SERVICE MANUAL
YFM5FGY
YFM5FGPY
YFM7FGY
YFM7FGPY
LIT-11616-22-19
34D-28197-10
EAS20050
YFM5FGY/YFM5FGPY/YFM7FGY/YFM7FGPY
SERVICE MANUAL
2008 by Yamaha Motor Corporation, U.S.A.
First edition, May 2008
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-22-19
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS20081
NOTICE
TIP
EAS20090
NOTICE
2
4
5
6
EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
TIP
T.
R.
10
E
11
12
M
13
BF
14
B
15
LS
16
M
17
18
LT
New
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
DRIVE TRAIN
ELECTRICAL SYSTEM
TROUBLESHOOTING
10
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
(YFM5FGP/YFM7FGP only)..................................................................... 1-5
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM
(YFM5FGP/YFM7FGP only)..................................................................... 1-7
INSTRUMENT FUNCTIONS ..................................................................... 1-9
IMPORTANT INFORMATION ....................................................................... 1-11
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-11
REPLACEMENT PARTS.........................................................................1-11
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-11
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-11
BEARINGS AND OIL SEALS .................................................................. 1-12
CIRCLIPS ................................................................................................1-12
CHECKING THE CONNECTIONS ................................................................1-13
SPECIAL TOOLS .......................................................................................... 1-14
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
EAS20150
MODEL LABEL
The model label 1 is affixed to the location
shown in the illustration. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20170
FEATURES
EAS28P1031
2 3 4
15
1.
2.
3.
4.
5.
6.
7.
8.
14
6 7 8
13 12
10
11
9. Fuel injector
10. Fuel pump
11. Speed sensor
12. Crankshaft position sensor
13. Coolant temperature sensor
14. Spark plug
15. Ignition coil
1-2
FEATURES
EAS28P1032
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm, 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature
sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.
Illustration is for reference only.
7
3
12
14
B
13
11
10
9
8
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Speed sensor
6. Lean angle sensor
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Intake air pressure sensor
10. Throttle body
11. ISC (idle speed control) unit
12. Throttle position sensor
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
1-4
FEATURES
EAS28P1033
6
8
1-5
FEATURES
1.
2.
3.
4.
5.
6.
7.
8.
a.
b.
c.
d.
e.
f.
ECA28P1027
NOTICE
1-6
FEATURES
EAS28P1034
18
7
8
9
10
17
16
11
5
12
13
14
1-7
15
FEATURES
1. EPS unit
2. Torque sensor
3. EPS motor
4. EPS control unit
5. Battery
6. Engine rpm signal
7. Coolant temperature sensor signal
8. Crankshaft position sensor signal
9. Speed sensor signal
10. ECU (engine control unit)
11. Intake air temperature sensor signal
12. Throttle position sensor signal
13. Intake air pressure sensor signal
14. Lean angle sensor signal
15. Ignition coil
16. Fuel pump
17. Fuel injector
18. Meter assembly
Multifunction display:
Speedometer/Odometer/Tripmeter A/Trip
meter B/Clock/Fuel meter/Gear position
Indicator and warning lights: EPS
warning/Engine trouble warning/Coolant
temperature warning/Reverse
indicator/Neutral indicator/Park
indicator/High-range indicator/Low-range
indicator/Differential lock
FI and EPS self-diagnostic fault codes
1-8
FEATURES
Clock mode
Pushing the CLOCK button switches the display between the clock mode CLOCK and the
hour meter mode HOUR in the following order:
CLOCK HOUR CLOCK
To set the clock:
1. Set the display to the clock mode.
2. Push the SELECT button and RESET button together for at least three seconds.
3. When the hour digits start flashing, push the
RESET button to set the hours.
4. Push the SELECT button, and the minute
digits will start flashing.
5. Push the RESET button to set the minutes.
6. Push the SELECT button and then release
it to start the clock.
EAS28P1035
INSTRUMENT FUNCTIONS
Multifunction display
3
2
1
7
1.
2.
3.
4.
5.
6.
7.
CLOCK button
RESET button
SELECT button
Speedometer
Fuel meter
Clock/Hour meter
Odometer/Tripmeter A/Tripmeter B
Fuel meter
2
3
TIP
TIP
1-9
FEATURES
Self-diagnosis device
This model is equipped with a self-diagnosis device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit fault
code. If the multifunction display indicates such
a fault code, note the code number, and check
the vehicle.
ECA28P1028
NOTICE
1-10
IMPORTANT INFORMATION
EAS20180
IMPORTANT INFORMATION
EAS20190
EAS20210
1.
2.
3.
4.
EAS20220
Oil
Lip
Spring
Grease
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-11
IMPORTANT INFORMATION
EAS20230
NOTICE
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
1-12
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
3. Check:
All connections
Loose connection Connect properly.
TIP
4. Connect:
Lead
Coupler
Connector
TIP
1-13
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
For U.S.A. and Canada, use part numbers starting with YM-, YU-, or ACC-.
For others, use part numbers starting with 90890-.
Tool name/Tool No.
Reference
pages
Illustration
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-13, 9-81,
9-82, 9-83,
9-87, 9-89,
9-90, 9-91,
9-92, 9-93,
9-94, 9-95,
9-96, 9-97,
9-98
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
3-5
3-5
YM-A5970
10
3
Digital tachometer
90890-06760
YU-39951-B
3-8
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-8
1-14
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Compression gauge
90890-03081
Engine compression tester
YU-33223
3-9
Extension
90890-04082
3-9
3-11
3-28
3-31, 3-32
4-57, 4-61
4-57, 4-61
4-57
5-18, 5-20
1-15
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Weight
90890-01084
YU-01083-3
Reference
pages
5-18
YU-01083-3
5-22, 5-27
5-22, 5-27
5-23
5-23
5-23
1-16
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
5-29
YU-01304
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-36, 5-37,
5-38, 5-50,
5-54
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-36
5-38, 5-66
5-42, 7-7
5-50, 5-53
1-17
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Locknut wrench
90890-01348
YM-01348
5-50, 5-53
5-50, 5-53
5-58, 5-59
5-70
1-18
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
5-72
YU-90058/YU-90059
5-72
Adapter (M16)
90890-04130
Adapter #13
YM-04059
5-72
5-72
YM-91044
Spacer
90890-01309
Pot spacer
YU-90059
35
5-72
5-82, 5-85
1-19
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
5-83, 5-84
5-83, 5-84
5-86, 8-29
6-3
YU-24460-01
6-3
YU-33984
6-9
1-20
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
6-9
Pressure gauge
90890-03153
YU-03153
7-7
7-7
8-13
M10P1.25
8-13
8-29
M14P1.5
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
9-91
1-21
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-10
ELECTRICAL SPECIFICATIONS .................................................................2-13
TIGHTENING TORQUES .............................................................................. 2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16
ENGINE TIGHTENING TORQUES......................................................... 2-17
CHASSIS TIGHTENING TORQUES.......................................................2-20
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-24
ENGINE................................................................................................... 2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-27
LUBRICATION DIAGRAMS .................................................................... 2-27
COOLING SYSTEM DIAGRAMS .................................................................. 2-31
CABLE ROUTING ......................................................................................... 2-33
GENERAL SPECIFICATIONS
EAS29110
GENERAL SPECIFICATIONS
Model
Model
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
Weight
With oil and fuel
Maximum loading limit
2-1
ENGINE SPECIFICATIONS
EAS29120
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Standard compression pressure (at sea level)
Minimummaximum
Starting system
Fuel
Recommended fuel
Fuel tank capacity
Fuel reserve amount
Engine oil
Lubrication system
Type
Wet sump
YAMALUBE 4 5W-30 or 10W-40 or 20W-50,
SAE 5W-30 or SAE 10W-40 or SAE 20W-50
API service SG type or higher, JASO standard
MA
2-2
ENGINE SPECIFICATIONS
Oil filter
Oil filter type
Cartridge (paper)
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Pressure check location
Trochoid
Less than 0.12 mm (0.0047 in)
0.20 mm (0.0079 in)
0.0900.170 mm (0.00350.0067 in)
0.24 mm (0.0094 in)
0.030.10 mm (0.00120.0039 in)
0.17 mm (0.0067 in)
Cylinder head
Cooling system
Radiator capacity (including all routes)
1.99 L (2.10 US qt, 1.75 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
From low to full level
0.14 L (0.15 US qt, 0.12 Imp.qt)
Radiator cap opening pressure
93.3122.7 kPa (0.951.25 kgf/cm, 13.517.8
psi)
Valve relief pressure
4.9 kPa (0.05 kgf/cm, 0.7 psi)
Thermostat
Model/manufacturer
3B4/NIPPON THERMOSTAT
Valve opening temperature
5054 C (122129 F)
Valve full open temperature
70 C (158 F)
Valve lift (full open)
7.0 mm (0.28 in)
Radiator core
Width
248.2 mm (9.77 in)
Height
340 mm (13.4 in)
Depth
22 mm (0.87 in)
Water pump
Water pump type
Single suction centrifugal pump
Reduction ratio
32/31 (1.032)
Impeller shaft tilt limit
0.15 mm (0.006 in)
Spark plug
Manufacturer/model
Spark plug gap
NGK/LMAR6A-9
0.80.9 mm (0.0310.035 in)
Cylinder head
Volume
51.4054.40 cm (YFM5FGY/YFM5FGPY)
56.7060.30 cm (YFM7FGY/YFM7FGPY)
0.03 mm (0.0012 in)
Warpage limit
Camshaft
Drive system
2-3
ENGINE SPECIFICATIONS
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
B
Camshaft runout limit
Timing chain
Model/number of links
Tensioning system
98XRH2010/126
Automatic
A
Valve face width B (intake)
2-4
ENGINE SPECIFICATIONS
Valve face width B (exhaust)
B
Valve seat width C (intake)
Limit
Valve seat width C (exhaust)
Limit
C
Valve margin thickness D (intake)
Limit
Valve margin thickness D (exhaust)
Limit
D
Valve stem diameter (intake)
Limit
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
Valve guide inside diameter (exhaust)
Limit
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide clearance (exhaust)
Limit
Valve stem runout
Valve spring
Free length (intake)
Limit
Free length (exhaust)
Limit
Installed length (intake)
Installed length (exhaust)
2-5
ENGINE SPECIFICATIONS
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Installed compression spring force (intake)
Clockwise
Clockwise
Cylinder
Bore
Wear limit
Taper limit
Out of round limit
Piston
Piston-to-cylinder clearance
Limit
Diameter D
Height H
Offset
Offset direction
Piston pin bore inside diameter
Limit
Piston pin outside diameter
2-6
ENGINE SPECIFICATIONS
Limit
Piston-pin-to-piston-pin-bore clearance
Limit
Piston ring
Top ring
Ring type
Dimensions (B T)
Barrel
1.20 3.50 mm (0.05 0.14 in)
(YFM5FGY/YFM5FGPY)
1.20 3.80 mm (0.05 0.15 in)
(YFM7FGY/YFM7FGPY)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
2nd ring
Ring type
Dimensions (B T)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
Oil ring
Dimensions (B T)
B
T
End gap (installed)
Ring side clearance
Crankshaft
Width A
2-7
ENGINE SPECIFICATIONS
Runout limit C
Big end side clearance D
D
A
Balancer
Balancer drive method
Gear
Clutch-stall revolution
V-belt
V-belt width
Limit
Transmission
Transmission type
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Operation
Single speed automatic
Low range
High range
Reverse gear
Drive axle runout limit
V-belt automatic
V-belt
Shaft drive
41/21 24/18 33/9 (9.544)
Left hand operation
2.3800.700 :1
31/16 (1.938)
31/27 (1.148)
23/14 28/23 (2.000)
0.06 mm (0.0024 in)
Shifting mechanism
Shift mechanism type
Shift fork-R, -L thickness
Decompression device
Device type
Auto decomp
Air filter
Air filter element
Air filter oil grade
Wet element
Foam air filter oil
2-8
ENGINE SPECIFICATIONS
Fuel pump
Pump type
Model/manufacturer
Electrical
3B4/DENSO
Throttle body
Type/quantity
Manufacturer
ID mark
40EIS/1
MIKUNI
28P1 00 (YFM5FGY/YFM5FGPY)
43P1 00 (YFM7FGY/YFM7FGPY)
#50
2975101010/1
DENSO
Idling condition
Engine idling speed
Intake vacuum
15501650 r/min
33.0 kPa (248 mmHg, 9.7 inHg)
(YFM5FGY/YFM5FGPY)
35.0 kPa (263 mmHg, 10.3 inHg)
(YFM7FGY/YFM7FGPY)
85.095.0 C (185.0203.0 F)
(YFM5FGY/YFM5FGPY)
75.085.0 C (167.0185.0 F)
(YFM7FGY/YFM7FGPY)
80.090.0 C (176.0194.0 F)
(YFM5FGY/YFM5FGPY)
55.065.0 C (131.00149.0 F)
(YFM7FGY/YFM7FGPY)
3.05.0 mm (0.120.20 in)
Less than 12 mm (0.47 in)
Water temperature
Oil temperature
2-9
CHASSIS SPECIFICATIONS
EAS29130
CHASSIS SPECIFICATIONS
Chassis
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread rear (STD)
Tread front (STD)
Toe-in (with tire touching the ground)
Front wheel
Wheel type
Rim size
Rim material
Panel wheel
12 6.0 AT
Steel (for models equipped with steel wheels)
Aluminum (for models equipped with aluminum
wheels)
180 mm (7.1 in)
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Rear wheel
Wheel type
Rim size
Rim material
Panel wheel
12 7.5 AT
Steel (for models equipped with steel wheels)
Aluminum (for models equipped with aluminum
wheels)
230 mm (9.1 in)
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Front tire
Type
Size
Manufacturer/model
Wear limit (front)
Tubeless
AT25 812
DUNLOP/KT421
3 mm (0.12 in)
Rear tire
Type
Size
Manufacturer/model
Wear limit (rear)
Tubeless
AT25 1012
DUNLOP/KT425
3 mm (0.12 in)
2-10
CHASSIS SPECIFICATIONS
Front brake
Type
Operation
Front brake lever free play (lever end)
Front disc brake
Disc outside diameter thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Rear brake
Type
Operation
Rear brake lever free play (lever end)
Brake pedal free play
Rear disc brake
Disc outside diameter thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Steering
Steering bearing type
Steering tension
Front suspension
Type
Spring/shock absorber type
Wheel travel
Shock absorber travel
Double wishbone
Coil spring/oil damper
180 mm (7.1 in)
90.2 mm (3.55 in) (YFM5FGY/YFM5FGPY)
90.7 mm (3.57 in) (YFM7FGY/YFM7FGPY)
292.0 mm (11.50 in)
233.1 mm (9.18 in) (YFM5FGY/YFM5FGPY)
233.5 mm (9.19 in) (YFM7FGY/YFM7FGPY)
23.00 N/mm (2.35 kgf/mm, 131.33 lb/in)
0.090.2 mm (0.003.55 in)
(YFM5FGY/YFM5FGPY)
0.090.7 mm (0.003.57 in)
(YFM7FGY/YFM7FGPY)
No
2-11
CHASSIS SPECIFICATIONS
Spring preload adjusting positions
Minimum
Standard
Maximum
1
3
5
Rear suspension
Type
Spring/shock absorber type
Wheel travel
Rear shock absorber assembly travel
Spring free length
Double wishbone
Coil spring/oil damper
230 mm (9.1 in)
109.2 mm (4.30 in)
318.1 mm (12.52 in) (YFM5FGY/YFM5FGPY)
314.5 mm (12.38 in) (YFM7FGY/YFM7FGPY)
270.6 mm (10.65 in) (YFM5FGY/YFM5FGPY)
267.5 mm (10.53 in) (YFM7FGY/YFM7FGPY)
31.00 N/mm (3.16 kgf/mm, 177.01 lb/in)
(YFM5FGY/YFM5FGPY)
33.50 N/mm (3.42 kgf/mm, 191.29 lb/in)
(YFM7FGY/YFM7FGPY)
36.00 N/mm (3.67 kgf/mm, 205.56 lb/in)
(YFM7FGY/YFM7FGPY)
0.0109.2 mm (0.004.30 in)
(YFM5FGY/YFM5FGPY)
0.043.0 mm (0.001.69 in)
(YFM7FGY/YFM7FGPY)
43.0109.2 mm (1.694.30 in)
(YFM7FGY/YFM7FGPY)
No
Installed length
Spring rate K1
Spring rate K2
Spring stroke K1
Spring stroke K2
Optional spring available
Spring preload adjusting positions
Minimum
Standard
Maximum
1
3
5
2-12
ELECTRICAL SPECIFICATIONS
EAS29140
ELECTRICAL SPECIFICATIONS
Voltage
System voltage
12 V
Ignition system
Ignition system
Advancer type
Ignition timing (B.T.D.C.)
TCI (digital)
Digital
5.0/1600 r/min
F8T83872/MITSUBISHI
(YFM5FGY/YFM5FGPY)
F8T83874/MITSUBISHI
(YFM7FGY/YFM7FGPY)
459561 at 20 C (68 F)
3.754.25 V
290390 at 80 C (176 F)
2.45 k at 20 C (68 F)
290354 at 80 C (176 F)
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
2JN/YAMAHA
6.0 mm (0.24 in)
2.162.64 at 20 C (68 F)
8.6412.96 k at 20 C (68 F)
Resin
10.0 k
AC magneto
Model/manufacturer
Standard output
Stator coil resistance
F4T39373/MITSUBISHI
14.0 V 34.0 A at 5,000 r/min
0.1080.132 at 20 C (68 F)
Rectifier/regulator
Regulator type
Model/manufacturer
Regulated voltage (DC)
Rectifier capacity (DC)
Withstand voltage
Battery
Model
Voltage, capacity
Manufacturer
Ten hour rate amperage
YTX20L-BS
12 V, 18.0 Ah
GS YUASA
1.8 A
2-13
ELECTRICAL SPECIFICATIONS
Headlight
Bulb type
Halogen bulb
12 V, 35.0/35.0 W 2
12 V, 5.0/21.0 W 1
EL
Constant mesh
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Mica undercut (depth)
SM-17/MITSUBA
0.80 kW
0.00500.0150 at 20 C (68 F)
12.0 mm (0.47 in)
6.50 mm (0.26 in)
6.026.51 N (614664 gf, 21.6923.45 oz)
0.70 mm (0.03 in)
Starter relay
Model/manufacturer
Amperage
Coil resistance
2768113-A/JIDECO
180.0 A
4.184.62 at 20 C (68 F)
19.0021.00
139.00141.00
Auxiliary DC output
Jack capacity
12 V, 10.0 A (120 W)
ACM33211/MATSUSHITA
86.4105.6
ACM33211/MATSUSHITA
86.4105.6
2-14
ELECTRICAL SPECIFICATIONS
Headlight relay
Model/manufacturer
Coil resistance
G8HN-1C4T-DJ/OMRON
94.5115.5
ACM33211/MATSUSHITA
86.4105.6
G8HN-1C4T-DJ/OMRON
94.5115.5
Circuit breaker
Circuit breaker type
Fuse
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Auxiliary DC jack fuse
Fuel injection system fuse
Four-wheel-drive motor fuse
EPS fuse
Spare fuse
Spare fuse
Spare fuse
Spare fuse
40.0 A
15.0 A
5.0 A
15.0 A
20.0 A
15.0 A
15.0 A
15.0 A
40.0 A (YFM5FGPY/YFM7FGPY)
40.0 A
20.0 A
15.0 A
5.0 A
2-15
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
A (nut) B (bolt)
General tightening
torques
Nm
mkg
ftlb
10 mm
6 mm
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
2-16
TIGHTENING TORQUES
EAS20340
Thread
Qty
size
Tightening torque
Remarks
M8
Muffler bolt
M8
M8
M6
Purging bolt
M10
M6
M36
M14
M6
11
M16
AC magneto/crankshaft position
sensor lead holder bolt
M5
LT
M8
LT
M6
12
M6
M6
M6
M16
M16
M36
M6
M22
Left-hand
thread
Stake.
M
Cylinder bolt
M10
Cylinder bolt
M6
M8
M9
M9
M6
M6
M6
M6
2-17
See TIP.
E
M
E
TIGHTENING TORQUES
Item
Thread
Qty
size
Tightening torque
Remarks
M8
M6
M7
M7
M6
M6
LT
M6
LT
M16
M6
M8
M14
M10
M6
Crankcase bolt
M8
Crankcase bolt
M6
Crankcase bolt
M6
M6
M14
M20
M20
LT
M6
LT
M6
LT
M6
M5
M10
Use a
lock
washer.
M18
Use a
lock
washer.
M6
M6
M6
M6
M6
M6
M6
M14
M14
2-18
TIGHTENING TORQUES
Thread
Qty
size
Item
Tightening torque
Remarks
Stake.
M22
M8
M8
M16
M55
M8
M60
M16
M6
M6
Spark plug
M10
M6
LT
M5
LT
M12
M6
Reverse switch
M10
M6
LT
Stake.
LT
Left-hand
thread
LT
Left-hand
thread
LT
LT
TIP
Temporarily tighten the cylinder bolts to 15 Nm (1.5 mkg, 11 ftlb) and then tighten them to 50 Nm (5.0
mkg, 36 ftlb).
Cylinder head tightening sequence:
5
7
3
1
6
2-19
TIGHTENING TORQUES
EAS20350
Thread
Qty
size
Tightening torque
M10
M6
M10
M6
M10
M10
M10
M6
M6
M6
M14
M6
M6
M8
Radiator bolt
M6
M6
M6
M6
M6
M6
M6
M5
M6
M10
M6
Footrest bolt
M6
M8
M6
M8
M8
M6
M6
2-20
Remarks
LT
LT
LT
Left-hand
thread
TIGHTENING TORQUES
Item
Thread
Qty
size
Tightening torque
Remarks
M6
M8
M6
M10
M6
M10
M20
M10
M20
M8
M8
M8
M8
M10
M6
M8
M10
M12
M10
M10
LS
M10
LS
M10
M6
M6
M6
M6
M10
M10
LS
M10
LS
M10
M6
M6
M6
M6
M6
M10
2-21
Stake.
Stake.
LT
LT
TIGHTENING TORQUES
Item
Thread
Qty
size
Tightening torque
M8
M8
M6
M6
M6
M6
M6
Remarks
Left-hand
thread
S
Left-hand
thread
M6
M6
M6
M10
M8
M10
LT
M8
LT
M14
M10
M22
M8
LT
M8
LT
M16
M6
M10
M10
M10
M10
M10
M14
2-22
LT
Left-hand
thread
LT
TIGHTENING TORQUES
Item
Thread
Qty
size
Tightening torque
M10
M8
M6
M14
M10
M14
M14
M8
M8
11
M8
M6
M6
M6
M6
M6
Rectifier/regulator bolt
M6
M6
M6
2-23
Remarks
LT
ENGINE
Lubrication point
Oil seal lips
Lubricant
LS
Bearings
O-rings
LS
Crankshaft pin
Crankshaft sprocket
Crankshaft seal
Piston pin
Camshaft lobes
Decompressor lever
LS
Torque limiter
LS
2-24
Lubricant
Shift drum
LS
Shift lever 1
Yamaha bond
No.1215 (Three bond
No.1215)
Yamaha bond
No.1215 (Three bond
No.1215)
2-25
2-26
LUBRICATION DIAGRAMS
A
3
A-A
2-27
2-28
2-29
Camshaft
Crankshaft
Oil strainer
Oil pump rotor
Oil pump driven gear
2-30
2-31
2-32
CABLE ROUTING
EAS20430
CABLE ROUTING
1
5 6 7
8
9
B
G
D
F
E
2
1
A-A
8 9
1 2
8
U
B-B
A
A
10 J
11 K
11
10
12 L
Q
16
15
14
C-C
M
11
13
D-D
P
2-33
CABLE ROUTING
R. Pass the final drive case breather hose through the
guide on the meter bracket.
S. Fasten the front brake light switch lead, oncommand four-wheel-drive motor switch and
differential gear lock switch lead, left handlebar
switch lead, and rear brake light switch lead with a
plastic locking tie. Be sure to fasten the plastic
locking tie above the couplers and fasten it around
the protective sleeves of the leads, not the leads
themselves.
T. 2050 mm (0.791.97 in)
U. Fasten the front brake light switch lead and oncommand four-wheel-drive motor switch and
differential gear lock switch lead with the plastic
bands at the bends in the handlebar, making sure
to route the leads under the handlebar and to face
the ends of the bands forward.
2-34
CABLE ROUTING
6
4 5 A
1 2 3
8 B
A
B
J
I
AC
10
15
G
11
12
F 14 E 13 D
A-A
Q
13
13
9 L
16
B-B
B-B
11 N
12 N
13
13
15
1
17
4
K
C-C
10 N O
19
1
K
D
C-C
2-35
18 P
CABLE ROUTING
R. YFM5FG/YFM7FG
1.
2.
3.
4.
2-36
CABLE ROUTING
4 5 6 7 B
8 9 C
2 A
E 10 11
12 13 14 15 F
B
D
16
A
G
25
24
23
17
22
21 I
19
20
25
5
8
4
24
18 H
26
1
M
17
6
1
A-A
13
B-B
27
13
18
14
D-D
12
E-E
20
20
13
27
E-E
2-37
19
S
F-F
G-G
CABLE ROUTING
L. Face the end of the plastic band inward.
M. Pass the plastic band through the hole in the
plastic cover, and then fasten the wire harness,
final drive case breather hose, ground lead, and
starter motor lead with the band, making sure to
face the end of the band downward.
N. The ends of the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose should extend rearward past the
inlet of air filter case as shown in the illustration.
O. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose under the air chamber.
P. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose rearward and pass them through the
guide.
Q. Insert the projection on each coupler into the hole
in the frame from the inside of the frame.
(YFM5FGP/YFM7FGP only)
R. Face the end of the plastic band inward.
S. Fasten the spark plug lead with the larger diameter
section of each holder.
T. YFM5FGP/YFM7FGP
U. YFM5FG/YFM7FG
1. Wire harness
2. Fuel hose
3. Intake air temperature sensor lead
4. Final drive case breather hose
5. Ground lead
6. Starter motor lead
7. Air filter case breather hose
8. Coolant temperature sensor lead
9. Throttle body breather hose
10. Main switch lead
11. Auxiliary DC jack lead
12. EPS motor lead (YFM5FGP/YFM7FGP only)
13. Differential motor lead
14. EPS torque sensor lead (YFM5FGP/YFM7FGP
only)
15. Radiator fan motor lead
16. Radiator inlet hose
17. EPS motor breather hose (YFM5FGP/YFM7FGP
only)
18. Spark plug lead
19. Rear brake cable
20. Shift control cable
21. Fuel tank drain hose
22. Gear position switch lead
23. Speed sensor lead
24. AC magneto/crankshaft position sensor lead
25. Fuel injector lead
26. Radiator fan motor breather hose
27. EPS torque sensor coupler (YFM5FGP/YFM7FGP
only)
A. Route the fuel hose between the wire harness and
the fuel tank drain hose.
B. Route the air filter case breather hose to the
outside of the leads, and then fasten the hose with
the holder on V-belt cooling intake duct joint.
C. Route the throttle body breather hose under the
coolant temperature sensor lead.
D. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose above the V-belt cooling intake duct.
E. Route the final drive case breather hose above the
V-belt cooling intake duct.
F. Route the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
G. Fasten the radiator fan motor lead and radiator fan
motor breather hose to the frame with the plastic
band, making sure to face the end of the band
inward.
H. Route the spark plug lead to the outside of the rear
brake cable and shift control cable.
I. Route the fuel tank drain hose to the inside of the
leads and fuel hose, making sure to position the
end of the drain hose as shown in the illustration.
J. Fasten the final drive case breather hose, ground
lead, starter motor lead, fuel injector lead, coolant
temperature sensor lead, AC magneto/crankshaft
position sensor lead, and wire harness with the
plastic band, making sure to position the band near
the split in the wire harness.
K. Route the fuel injector lead and coolant
temperature sensor lead to the inside of the ground
lead, starter motor lead, final drive case breather
hose, and wire harness.
2-38
CABLE ROUTING
C
C
6
6
2
3
A-A
B-B
2-39
C-C
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
A.
B.
C.
D.
E.
F.
2-40
CABLE ROUTING
B
8
33
32
31
D
9
30 O
29
10
A
11
E
M
28
12
27
13
26
25
24
14
15
23
16
L
22
21
J 20 I
H 11 19
33 32 31 22 Q
18 G 17
34
7
R
B-B
A-A
2-41
CABLE ROUTING
L. Pass the coolant reservoir breather hose through
the guides on the plastic cover and electrical
components tray and route it under the positive
battery lead and starter motor lead.
M. Route the hoses under the positive battery lead,
and then route them upward, to the inside of the
coolant reservoir breather hose.
N. Fasten the coolant reservoir breather hose with the
holder on the electrical components tray.
O. Fasten the coolant reservoir hose with the holder
on the electrical components tray.
P. Pass the hoses and ground lead through the
opening in the electrical components tray.
Q. Route the coolant reservoir breather hose above
the other hoses.
R. Route the hoses to the inside of the screw.
1.
2.
3.
4.
5.
6.
7.
8.
9.
2-42
CABLE ROUTING
4
3
6 B
7
C
8
9 D
20
E
F
G
10
11
12 H
13 H
14
15
16
19
17
1 K
A-A
C
L 14 11 10
18
18
B-B
2-43
C-C
CABLE ROUTING
1. Throttle cable
2. Rear brake hose
3. Rear brake cable
4. Front brake hose
5. Negative battery lead
6. Final drive case breather hose
7. Starter motor lead
8. Throttle body breather hose
9. Intake air pressure sensor lead
10. TPS lead
11. Intake air temperature sensor lead
12. Fuel injector lead
13. Coolant temperature sensor lead
14. Wire harness
15. AC magneto lead
16. Rectifier/regulator lead
17. Fuel hose
18. Tail/brake light lead
19. Fuel pump lead
20. ISC unit lead
A. Route the throttle cable under the plastic cover.
B. Route the final drive case breather hose on top of
the leads.
C. Fasten the radiator fan motor breather hose and
throttle body breather hose with the holder.
D. Route the intake air pressure sensor lead to the
front of the throttle body breather hose and above
the ISC unit lead.
E. Fasten the ISC unit lead with the holder.
F. To engine
G. To air filter case
H. Route the fuel injector lead and coolant
temperature sensor lead to the outside of the
frame.
I. Pass the tail/brake light lead through the hole in
the rear fender.
J. Fasten the tail/brake light lead with the holder,
making sure that the coupler is positioned to the
rear of the holder.
K. Pass the throttle cable through the guide on the
plastic cover.
L. Insert the projection on the wire harness holder
into the hole in the plastic cover.
2-44
CABLE ROUTING
2
A
C
C
4
4
B-B
D
E
E-E
2-45
CABLE ROUTING
1.
2.
3.
4.
A.
B.
C.
D.
E.
F.
2-46
CABLE ROUTING
2-47
PERIODIC MAINTENANCE
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EBU21742
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL
NO.
ITEM
CHECK OR MAINTENANCE
JOB
month
Whichever
comes first km (mi)
hours
EVERY
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
Fuel line
Check fuel hoses for cracks or other damage, and replace if necessary.
Spark plug
Valves
Crankcase breather
system
Exhaust system
Spark arrester
Clean.
2
3
EBU21864
NO.
ITEM
CHECK OR MAINTENANCE
JOB
month
Whichever
comes first km (mi)
hours
Front brake
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
Rear brake
EVERY
3-1
PERIODIC MAINTENANCE
INITIAL
NO.
ITEM
CHECK OR MAINTENANCE
JOB
month
Whichever
comes first km (mi)
hours
EVERY
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
Brake hoses
Wheels
Tires
V-belt
10
Chassis fasteners
Make sure that all nuts, bolts, and screws are properly tightened.
11
12
Stabilizer bushes
13
14
Steering shaft
Replace.
Every 4 years
15
Steering system
16
Engine mount
17
Axle boots
18
Engine oil
Change.
Check ATV for oil leakage, and correct if necessary.
19
Replace.
20
Change.
Check ATV for oil leakage, and correct if necessary.
21
Change.
Check ATV for oil leakage, and correct if necessary.
22
Cooling system
Replace coolant.
Every 2 years
23
Lubricate.
24
25
26
27
3-2
PERIODIC MAINTENANCE
EBU23070
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
3-3
ENGINE
EAS20472
ENGINE
1
EAS20520
TIP
6. Measure:
Valve clearance
Out of specification Adjust.
1. Remove:
Left side panel
Right side panel
Front fender
Footrest board
Air filter case
Refer to GENERAL CHASSIS on page 4-1.
2. Remove:
Intake tappet cover 1
Exhaust tappet cover
Camshaft sprocket cover 2
3. Disconnect:
Spark plug cap 1
4. Remove:
Spark plug 2
TIP
To position the piston at TDC on the compression stroke, align the I mark c on the camshaft
sprocket with the stationary pointer d on the
cylinder head, as shown in the illustration.
5. Remove:
Timing mark accessing screw 1
Crankshaft end accessing screw 2
c. Measure the valve clearance with a thickness
gauge 1.
3-4
ENGINE
Out of specification Adjust.
T.
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
R.
8. Install:
Timing mark accessing screw
Crankshaft end accessing screw
1
T.
R.
7. Adjust:
Valve clearance
9. Install:
Spark plug
T.
R.
O-rings 1 New
Camshaft sprocket cover
Intake tappet cover
Exhaust tappet cover
T.
Direction a
Valve clearance is increased.
Direction b
Valve clearance is decreased.
R.
Spark plug
13 Nm (1.3 mkg, 9.4 ftlb)
10.Connect:
Spark plug cap
11.Install:
1
New
3
1
2
12.Install:
Air filter case
Footrest board
Front fender
Right side panel
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
3-5
ENGINE
EAS20660
TIP
Handlebar side
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting bolt 3 in direction a or
b until the correct free play is obtained.
Direction a
Free play is increased.
Direction b
Free play is decreased.
2WD
4WD
a
2. Remove:
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
3. Adjust:
Throttle lever free play
a
2WD
4WD
WARNING
After adjusting the free play, turn the handlebar to the right and left to make sure that the
engine idling speed does not increase.
Direction a
Free play is increased.
Direction b
Free play is decreased.
4. Install:
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
EAS29170
2
1
3-6
ENGINE
2. Adjust:
Speed limiter length a
Manufacturer/model
NGK/LMAR6A-9
5. Check:
Electrode 1
Damage/wear Replace the spark plug.
Insulator 2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
Direction b
Speed limiter length is decreased.
Direction c
Speed limiter length is increased.
a
1
2
b
c
6. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
Spark plug gap a
(with a wire thickness gauge)
Out of specification Regap.
WARNING
EAS20690
8. Install:
Spark plug
T.
ECA13330
R.
NOTICE
Spark plug
13 Nm (1.3 mkg, 9.4 ftlb)
TIP
4. Check:
Spark plug type
Incorrect Change.
3-7
ENGINE
Incorrect firing range Check the ignition
system.
10.Install:
Right side panel
Refer to GENERAL CHASSIS on page 4-1.
TIP
EAS20700
b
a
d. Install the timing mark accessing screw.
T.
R.
Digital tachometer
90890-06760
YU-39951-B
Timing light
90890-03141
Inductive clamp timing light
YU-03141
4. Detach:
Timing light
Tachometer
5. Install:
Footrest board
Right side panel
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
3. Check:
Ignition timing
EAS20710
a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
TIP
1. Measure:
Valve clearance
Out of specification Adjust.
Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
Right side panel
Refer to GENERAL CHASSIS on page 4-1.
4. Disconnect:
Spark plug cap
5. Remove:
Spark plug
3-8
ENGINE
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits Eliminate.
d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure
again.
Refer to the following table.
Compression pressure (with oil applied into
the cylinder)
ECA28P1041
NOTICE
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from
falling into the cylinder.
6. Attach:
Extension 1
Compression gauge 2
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
Reading
Diagnosis
8. Install:
Spark plug
T.
7. Measure:
Compression pressure
Out of specification Refer to steps (c) and
(d).
R.
Spark plug
13 Nm (1.3 mkg, 9.4 ftlb)
9. Connect:
Spark plug cap
10.Install:
Right side panel
Refer to GENERAL CHASSIS on page 4-1.
EAS20750
WARNING
3-9
ENGINE
ECA28P1009
NOTICE
To obtain an accurate oil level reading, the dipstick must be inserted completely into the oil filter hole.
5. Check the engine oil level again.
ECA28P1010
NOTICE
b
a
EAS20780
Type
YAMALUBE 4 5W-30 or 10W-40
or 20W-50, SAE 5W-30 or SAE
10W-40 or SAE 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
10
30
50
70
90
110
130F
-20
-10
10
20
30
40
50C
ECA28P1004
NOTICE
5. Remove:
Engine oil drain bolt 1
(along with the gasket)
3-10
ENGINE
T.
6. Drain:
Engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
R.
10.Fill:
Crankcase
(with the specified amount of the recommended engine oil)
11.Install:
Dipstick
12.Start the engine, warm it up for several minutes, and then turn it off.
13.Check:
Engine
(for engine oil leaks)
14.Check:
Engine oil level
Refer to CHECKING THE ENGINE OIL
LEVEL on page 3-9.
15.Check:
Engine oil pressure
NOTICE
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
R.
8. Check:
Engine oil drain bolt gasket
Damage Replace.
9. Install:
Engine oil drain bolt
(along with the gasket)
3-11
ENGINE
ECA28P1011
NOTICE
T.
R.
EAS20951
1
4. Check:
Air filter element
Air filter element frame
Damage Replace.
5. Clean:
Air filter element
(with solvent)
EWA13020
WARNING
ECA13430
NOTICE
3. Remove:
Air filter element 1
Air filter element frame 2
3-12
ENGINE
V-belt width
33.3 mm (1.31 in)
Limit
30.0 mm (1.18 in)
6. Apply the recommended oil to the entire surface of the air filter element and then carefully
pat the air filter element on a clean cloth to remove the excess oil. The air filter element
should be wet but not dripping.
4. Install:
Drive belt cover
Refer to PRIMARY AND SECONDARY
SHEAVES on page 5-47.
EAS28P1006
TIP
Make sure the air filter element and air filter element frame are properly installed in the air filter
case.
8. Install:
Right side panel
Left side panel
Fuel tank cover
Refer to GENERAL CHASSIS on page 4-1.
EAS20970
3-13
ENGINE
Rear fender
Refer to GENERAL CHASSIS on page 4-1.
V-belt cooling exhaust duct
Refer to ENGINE REMOVAL on page 5-1.
2. Check:
Fuel hose 1
Cracks/damage Replace.
Loose connection Connect properly.
Install the V-belt so that its arrow faces the direction shown in the illustration.
3. Install:
V-belt cooling exhaust duct
Refer to ENGINE REMOVAL on page 5-1.
Rear fender
Right side panel
Seat
Refer to GENERAL CHASSIS on page 4-1.
EAS21050
EAS21020
NOTICE
3. Install:
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
EAS21030
3. Install:
Air filter case
3-14
ENGINE
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
EWA28P1009
WARNING
EAS21080
T.
R.
10
8
8
2
5
1
c. Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.
d. Install the gasket, and then insert the tailpipe
into the muffler and align the bolt holes.
e. Insert the bolts 1 and tighten them.
6
6
T.
R.
EAS28970
3-15
ENGINE
3
3. If the coolant is at or below the minimum level
mark, remove the left side panel.
Refer to GENERAL CHASSIS on page 4-1.
4. Remove the reservoir cap 1, add coolant or
distilled water to the maximum level mark a,
install the reservoir cap, and then install the
panel.
T.
R.
Purging bolt
27 Nm (2.7 mkg, 19 ftlb)
EAS21110
TIP
The coolant level must be checked on a cold engine since the level varies with engine temperature.
2. Check:
Coolant level
The coolant level should be between the minimum level mark a and maximum level mark
b.
Below the minimum level mark Add the
recommended coolant to the proper level.
ECA13470
NOTICE
3-16
EAS21120
ENGINE
1
2
2
3
4. Drain:
Coolant
(from the coolant reservoir)
5. Connect:
Coolant reservoir hose
6. Remove:
Radiator cap 1
EWA13030
WARNING
5
6
7
9
8
3. Install:
Left footrest board
Front fenders
Refer to GENERAL CHASSIS on page 4-1.
EAS21130
7. Remove:
Coolant drain bolt 1
(along with the copper washer)
TIP
3-17
Place a container under the engine, and then remove the coolant drain bolt. (Use a trough 2 or
a similar object as shown to prevent coolant
from spilling on the engine guard.)
ENGINE
EWA13040
WARNING
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
8. Drain:
Coolant
(from the engine and radiator)
9. Check:
Coolant drain bolt 1
Damage Replace.
10.Install:
ECA13480
NOTICE
T.
R.
12.Fill:
Coolant reservoir
(with the recommended coolant to the maximum level mark a)
13.Install:
Coolant reservoir cap 1
11.Fill:
Cooling system
(with the specified amount of the recommended coolant)
FULL
LOW
Recommended antifreeze
High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
1.99 L (2.10 US qt, 1.75 Imp.qt)
Coolant reservoir capacity (up to
the maximum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
14.Bleed:
Coolant system
3-18
ENGINE
1
T.
R.
T.
R.
3-19
CHASSIS
2. Check:
Brake pedal free play a
Out of specification Adjust.
EAS29360
CHASSIS
EAS21170
3. Adjust:
Brake pedal free play
EAS29180
WARNING
T.
R.
1. Check:
Rear brake lever free play a
Out of specification Bleed the rear brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
a
1
2
TIP
3-20
CHASSIS
A
2WD
4WD
6
B
6
4
A. Front brake
B. Rear brake
EWA13090
WARNING
EAS21240
ECA13540
EWA14900
WARNING
NOTICE
TIP
TIP
2. Check:
Brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Recommended fluid
DOT 4
3-21
CHASSIS
1. Remove:
Front wheels
Refer to FRONT WHEELS on page 4-14.
2. Operate the brake.
3. Check:
Front brake pads
A wear indicator groove a has almost disappeared Replace the brake pads and brake
pad spring as a set.
Refer to FRONT BRAKE on page 4-21.
EAS21280
4. Install:
Front wheels
Refer to FRONT WHEELS on page 4-14.
EAS21260
4. Install:
Rear wheels
Refer to REAR WHEELS on page 4-18.
2. Check:
Brake hose holders
Loose Tighten the holder bolt.
3. Apply the brake several times.
4. Check:
Brake hoses
Brake fluid leakage Replace the damaged
hose.
Refer to FRONT BRAKE on page 4-21.
EAS21290
3-22
CHASSIS
1
3. Install:
Rear wheels
Refer to REAR WHEELS on page 4-18.
EAS21350
WARNING
2. Check:
Brake hose holders
Loose Tighten the clamp bolt.
3. Apply the brake several times.
4. Check:
Brake hoses
Brake fluid leakage Replace any damaged
hose.
Refer to REAR BRAKE on page 4-32.
TIP
EAS28P1007
A. Protector is normal.
B. Protector is worn.
3-23
CHASSIS
3. Install:
Rear wheels
Refer to REAR WHEELS on page 4-18.
EAS29220
NOTICE
2
3
A. Front brake
B. Rear brake
TIP
Loosening the bleed screw will release the pressure and cause the brake lever to touch the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
T.
R.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
1.
2.
3.
4.
5.
6.
7.
N (neutral)
H (high)
L (low)
R (reverse)
P (park)
Drive select lever shift control cable
Drive select lever shift rod
1. Adjust:
Brake pedal free play
Refer to ADJUSTING THE REAR DISC
BRAKE on page 3-20.
2. Remove:
Left side panel
Refer to GENERAL CHASSIS on page 4-1.
3. Adjust:
Drive select lever shift control cable
Drive select lever shift rod
WARNING
3-24
CHASSIS
a
T.
R.
EAS21460
Type
SAE 80 API GL-4 Hypoid gear
oil
ECA28P1005
NOTICE
Take care not to allow foreign material to enter the final drive case.
3-25
CHASSIS
1
T.
R.
7. Fill:
Final drive case
(with the specified amount of the recommended final gear oil)
Total amount
0.25 L (0.26 US qt, 0.22 Imp.qt)
Periodic oil change
0.20 L (0.21 US qt, 0.18 Imp.qt)
Type
SAE 80 API GL-4 Hypoid gear
oil
4. Install:
Final gear oil level check bolt
T.
R.
EAS21470
NOTICE
Take care not to allow foreign material to enter the final drive case.
8. Check:
Oil level
Refer to CHECKING THE FINAL GEAR OIL
LEVEL on page 3-25.
9. Install:
Final gear oil level check bolt
Final gear oil filler bolt
T.
R.
4. Remove:
Final gear oil level check bolt
Final gear oil drain bolt 1
Completely drain the final drive case of its oil.
EAS29250
5. Check:
Final gear oil drain bolt gasket
Damage Replace.
6. Install:
Final gear oil drain bolt
(with the gasket)
ECA16170
NOTICE
Take care not to allow foreign material to enter the differential case.
3-26
CHASSIS
Periodic oil change
0.22 L (0.23 US qt, 0.19 Imp.qt)
Total amount
0.23 L (0.24 US qt, 0.20 Imp.qt)
Type
SAE 80 API GL-4 Hypoid gear
oil
ECA16170
NOTICE
Take care not to allow foreign material to enter the differential case.
4. Install:
Differential gear oil filler bolt
T.
R.
TIP
EAS29260
7. Check:
Oil level
Refer to CHECKING THE DIFFERENTIAL
GEAR OIL LEVEL on page 3-26
8. Install:
Differential gear oil filler bolt
T.
R.
EAS29270
4. Check:
Differential gear oil drain bolt gasket
Damage Replace.
5. Install:
Differential gear oil drain bolt
T.
R.
6. Fill:
Differential case
(with the specified amount of the recommended differential gear oil)
3-27
CHASSIS
A
A. Front
B. Rear
EAS29280
3. Check:
Tie-rod ends
Free play Replace the tie-rod end.
3-28
CHASSIS
d. Tighten the steering stem bracket bolts to
specification.
T.
R.
T.
R.
Steering tension
50 N (5.0 kgf)
(YFM5FGPY/YFM7FGPY)
TIP
EAS29290
TIP
a.
b.
c.
d.
Toe-in = B - A
T.
R.
3-29
CHASSIS
T.
R.
TIP
3. Adjust:
Toe-in
EWA14910
WARNING
3-30
EAS29300
CHASSIS
Refer to FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES on
page 4-59.
3. Check:
Operation
Pump the front shock absorber assembly up
and down several times.
Rough operation Replace front shock absorber assembly.
Refer to FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES on
page 4-59.
EAS29320
1
b
EAS29310
WARNING
3-31
CHASSIS
1 2
EAS29330
EAS29340
WARNING
EWA14930
WARNING
Tire characteristics
1. Adjust:
Spring preload
Turn the adjuster 1 in direction a or b.
EWA14950
WARNING
Front tire
Type
Tubeless
Size
AT25 812
Manufacturer/model
DUNLOP/KT421
Rear tire
Type
Tubeless
Size
AT25 1012
Manufacturer/model
DUNLOP/KT425
Tire pressure
EWA14960
WARNING
Tire pressure below the minimum specification could cause the tire to dislodge from
the rim under severe riding conditions.
3-32
CHASSIS
Use no more than the following pressures
when seating the tire beads.
Front
250 kPa (2.5 kgf/cm, 36 psi)
Rear
250 kPa (2.5 kgf/cm, 36 psi)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
Tire air pressure (measured on
cold tires)
Recommended
Front
35 kPa (0.35 kgf/cm, 5.0 psi)
Rear
30 kPa (0.30 kgf/cm, 4.4 psi)
Minimum
Front
32 kPa (0.32 kgf/cm, 4.6 psi)
Rear
27 kPa (0.27 kgf/cm, 4.0 psi)
WARNING
EWA14980
WARNING
Uneven or improper tire pressure may adversely affect the handling of this vehicle
and may cause loss of control.
Maintain proper tire pressures.
Set tire pressures when the tires are cold.
Tire pressures must be equal in both front
tires and equal in both rear tires.
2. Check:
Tire surfaces
Wear/damage Replace.
Wear limit (front)
3 mm (0.12 in)
Wear limit (rear)
3 mm (0.12 in)
EWA28P1006
WARNING
1. Measure:
Tire pressure
Out of specification Adjust.
3-33
CHASSIS
EAS21690
WARNING
TIP
1. Check:
Outer cable
Damage Replace.
2. Check:
Cable operation
Rough movement Lubricate.
Recommended lubricant
Engine oil or a suitable cable lubricant
TIP
EAS29350
3. Apply:
Lithium-soap-based grease
(onto end of the cable)
EAS21700
EWA14990
WARNING
Recommended lubricant
Silicone grease
TIP
EAS21710
Recommended lubricant
Lithium-soap-based grease
3-34
ELECTRICAL SYSTEM
Headlight bulb 2
EAS21750
ELECTRICAL SYSTEM
EWA13320
WARNING
EAS21760
TIP
EAS21770
Unhook the headlight bulb holder, and then remove the defective bulb.
EAS21790
5. Install:
NOTICE
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Remove:
Headlight bulb cover 1
6. Install:
Headlight bulb holder
7. Connect:
Headlight coupler
8. Install:
Headlight bulb cover
Cover at the rear of the headlight
3. Disconnect:
Headlight coupler 1
EAS21810
1
4. Remove:
Headlight bulb holder 1
3-35
ELECTRICAL SYSTEM
Direction a
Headlight beam is raised.
Direction b
Headlight beam is lowered.
b
1
3-36
ELECTRICAL SYSTEM
3-37
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
INSTALLING THE REAR FENDER........................................................... 4-6
INSTALLING THE FOOTREST BOARDS............................................... 4-12
FRONT WHEELS .......................................................................................... 4-14
REMOVING THE FRONT WHEELS .......................................................4-15
CHECKING THE FRONT WHEELS........................................................ 4-15
CHECKING THE FRONT WHEEL HUBS ............................................... 4-15
INSTALLING THE FRONT BRAKE DISCS............................................. 4-16
INSTALLING THE FRONT WHEEL HUBS ............................................. 4-16
INSTALLING THE FRONT WHEELS......................................................4-16
REAR WHEELS............................................................................................. 4-18
REMOVING THE REAR WHEELS.......................................................... 4-19
CHECKING THE REAR WHEELS .......................................................... 4-19
CHECKING THE REAR WHEEL HUBS.................................................. 4-19
INSTALLING THE REAR BRAKE DISCS ............................................... 4-19
INSTALLING THE REAR WHEEL HUBS................................................ 4-19
INSTALLING THE REAR WHEELS ........................................................ 4-20
FRONT BRAKE ............................................................................................. 4-21
INTRODUCTION .....................................................................................4-26
CHECKING THE FRONT BRAKE DISCS............................................... 4-26
REPLACING THE FRONT BRAKE PADS .............................................. 4-27
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-27
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-28
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-28
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-29
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-29
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-30
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-30
REAR BRAKE ...............................................................................................4-32
INTRODUCTION .....................................................................................4-38
CHECKING THE REAR BRAKE DISCS ................................................. 4-38
REPLACING THE REAR BRAKE PADS................................................. 4-38
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-39
DISASSEMBLING THE REAR BRAKE CALIPERS ................................4-39
CHECKING THE REAR BRAKE CALIPERS ..........................................4-40
ASSEMBLING THE REAR BRAKE CALIPERS ...................................... 4-40
INSTALLING THE REAR BRAKE CALIPERS ........................................ 4-40
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-41
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-41
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-41
HANDLEBAR ................................................................................................4-44
REMOVING THE HANDLEBAR..............................................................4-46
CHECKING THE HANDLEBAR ..............................................................4-46
INSTALLING THE HANDLEBAR ............................................................ 4-46
STEERING STEM.......................................................................................... 4-48
CHECKING THE STEERING STEM .......................................................4-52
INSTALLING THE STEERING STEM (for YFM5FG/YFM7FG) .............. 4-52
INSTALLING THE STEERING STEM (for YFM5FGP/YFM7FGP) .........4-52
INSTALLING THE PITMAN ARM (for YFM5FG/YFM7FG) .....................4-53
INSTALLING THE PITMAN ARM (for YFM5FGP/YFM7FGP) ................ 4-53
TIE-RODS AND STEERING KNUCKLES.....................................................4-55
REMOVING THE STEERING KNUCKLES ............................................. 4-56
CHECKING THE TIE-RODS ................................................................... 4-56
CHECKING THE STEERING KNUCKLES AND FRONT WHEEL
BEARINGS ............................................................................................. 4-56
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-56
INSTALLING THE TIE-RODS .................................................................4-58
INSTALLING THE FRONT ARM PROTECTORS ................................... 4-58
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-59
CHECKING THE FRONT ARMS............................................................. 4-61
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-61
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-61
INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES ......................................................................................... 4-62
INSTALLING THE FRONT ARM PROTECTORS ................................... 4-63
REAR KNUCKLES AND STABILIZER ......................................................... 4-64
CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ............................................................................................. 4-66
CHECKING THE STABILIZER................................................................4-66
INSTALLING THE REAR ARM PROTECTORS ..................................... 4-66
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 4-67
CHECKING THE REAR ARMS ...............................................................4-68
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-68
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES ......................................................................................... 4-68
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the engine skid plates
T.
R.
2
1
T.R
Order
Job/Parts to remove
Qty
Remarks
4-1
GENERAL CHASSIS
Removing the seat and side panels
2
1
4
6
Order
Job/Parts to remove
Qty
Remarks
TIP
1
Seat
Battery cover
4-2
GENERAL CHASSIS
Removing the front carrier and front guard
.
T.R
T.R
6
5
T.R
2
.
T.R
(4)
(4)
T.R
Order
Job/Parts to remove
Qty
Front carrier
1
Disconnect.
ECA28P1013
Battery lead
Battery
Upper panel
Front guard
NOTICE
First disconnect the negative battery
lead, then disconnect the positive lead.
4-3
GENERAL CHASSIS
Removing the front fenders and front grill
(3)
(3)
1
4
.
T.R
1
.
T.R
T.R
Order
Job/Parts to remove
Qty
Remarks
Seat/Side panels
Disconnect.
Disconnect.
Front fender
Headlight coupler
Front grill
Disconnect.
For installation, reverse the removal procedure.
4-4
GENERAL CHASSIS
Removing the rear carrier and rear fender
T.R
T.R
2
.
T.R
(4)
5
3
.
T.R
(6)
T.R
(6)
Order
Job/Parts to remove
Qty
Remarks
Refer to Removing the seat and side panels.
Seat/Side panels
1
Rear carrier
Storage compartment
Rear fender
Disconnect.
For installation, reverse the removal procedure.
4-5
GENERAL CHASSIS
EAS28P1002
T.
R.
TIP
4-6
GENERAL CHASSIS
Removing the electrical components tray 1/2
.
T.R
10
13
12
2
3
11
11
4
5
T.R
7 8
9
9
Order
14
Job/Parts to remove
Qty
Remarks
1
Disconnect.
ECA28P1013
NOTICE
Battery lead
Battery
Headlight relay
Disconnect.
YFM5FGP/YFM7FGP only
10
YFM5FGP/YFM7FGP only
11
ECU coupler
Disconnect.
12
4-7
Disconnect.
GENERAL CHASSIS
Removing the electrical components tray 1/2
.
T.R
10
13
12
2
3
11
11
4
5
T.R
7 8
9
9
Order
14
Job/Parts to remove
Qty
13
ECU bracket
14
Remarks
Disconnect.
For installation, reverse the removal procedure.
4-8
GENERAL CHASSIS
Removing the electrical components tray 2/2
.
T.R
15
11
10
14
7
19
89
(4)
3
6
5
4
12
13
20
2
17
16
18
.
T.R
T.R
Order
Job/Parts to remove
Qty
Starter relay
Fuse box
EPS fuse
Main fuse
Spare fuse
Remarks
Disconnect.
YFM5FGP/YFM7FGP only
10
Disconnect.
11
Disconnect.
12
Disconnect.
13
Disconnect.
14
Disconnect.
15
Meter assembly
16
17
4-9
Disconnect.
GENERAL CHASSIS
Removing the electrical components tray 2/2
.
T.R
15
11
10
14
7
19
89
(4)
3
6
5
4
12
13
20
2
17
16
18
.
T.R
T.R
Order
Job/Parts to remove
Qty
18
19
Wire harness
20
Disconnect.
4-10
GENERAL CHASSIS
Removing the footrest boards
T.R
(5)
(4)
1
T.R
2
3
2
(5)
(4)
(5)
(4)
(5)
3
.
T.R
(4)
T.R
Order
Job/Parts to remove
Qty
Seat/Side panels
1
Footrest
Footrest board
Footrest bracket
2
For installation, reverse the removal procedure.
4-11
GENERAL CHASSIS
EAS28P1003
T.
R.
TIP
FWD
2. Install:
Footrest
T.
R.
Footrest bolt
7 Nm (0.7 mkg, 5.1 ftlb)
TIP
4-12
GENERAL CHASSIS
Removing the air filter case
2
.
T.R
8
New
7
New
Order
Job/Parts to remove
Qty
Remarks
Refer to Removing the seat and side panels.
Seat/Side panels
1
Disconnect.
Loosen.
Disconnect.
1
For installation, reverse the removal procedure.
4-13
FRONT WHEELS
EAS21870
FRONT WHEELS
Removing the front wheels and brake discs
T.
R.
T.
LT
LT
R.
1
2
LT
3 New
T.
R.
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the front wheels.
Place the vehicle on a level surface.
Front wheel
Wheel cap
TIP
4
4-14
FRONT WHEELS
EAS21890
3. Check:
Wheel balance
Out of balance Adjust.
EWA15000
WARNING
EAS28P1008
4-15
FRONT WHEELS
2
1
2. Check:
Brake disc
Refer to CHECKING THE FRONT BRAKE
DISCS on page 4-26
EAS28P1009
EAS28P1011
T.
R.
TIP
TIP
Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.
EAS28P1010
2. Tighten:
Wheel nuts 1
T.
R.
Wheel nut
55 Nm (5.5 mkg, 40 ftlb)
EWA28P1007
WARNING
T.
R.
TIP
4-16
FRONT WHEELS
4-17
REAR WHEELS
EAS22020
REAR WHEELS
Removing the rear wheels and brake discs
T.
R.
T.
LT
LT
R.
1
2
LT
6
4
3 New
T.
R.
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear wheels.
Place the vehicle on a level surface.
Rear wheel
Wheel cap
TIP
4
4-18
REAR WHEELS
EAS22040
2
1
TIP
EAS28P1012
T.
R.
TIP
Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.
EAS28P1013
R.
T.
3. Check:
Wheel balance
Refer to CHECKING THE FRONT
WHEELS on page 4-15.
EAS29440
TIP
4-19
REAR WHEELS
2. Check:
Brake disc
Refer to CHECKING THE REAR BRAKE
DISCS on page 4-38.
EAS28P1014
2. Tighten:
Wheel nuts 1
T.
R.
Wheel nut
55 Nm (5.5 mkg, 40 ftlb)
EWA28P1007
WARNING
4-20
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
T.
R.
T.
R.
3
2
FW
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the front brake calipers.
Front wheel
1
For installation, reverse the removal procedure.
4-21
FRONT BRAKE
Removing the front brake master cylinder
T.
R.
1
11
2
3
12
7 New
T.
R.
6
9
10
4
T.
R.
R.
FW
Order
Job/Parts to remove
Qty
Remarks
Brake fluid
Drain.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
Brake lever
Union bolt
Copper washer
Disconnect.
Disconnect.
10
11
12
1
For installation, reverse the removal procedure.
4-22
FRONT BRAKE
Disassembling the front brake master cylinder
3 New
1
2 New
Order
FW
Job/Parts to remove
Qty
Dust boot
Circlip
Remarks
4-23
FRONT BRAKE
Removing the front brake calipers
T.
R.
3
6
T.
R.
FW
2 New
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
Brake fluid
Front wheel
Union bolt
Copper washer
Disconnect.
Loosen.
4-24
FRONT BRAKE
Disassembling the front brake calipers
T.
R.
8
3
BF
T.
R.
5
6 New
7 New
S
Order
FW
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the front brake calipers.
Brake pad
Bleed screw
1
For assembly, reverse the disassembly procedure.
4-25
FRONT BRAKE
EAS22220
INTRODUCTION
EWA14100
WARNING
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
Never disassemble brake components unless absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
Never use solvents on internal brake components.
Use only clean or new brake fluid for cleaning brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get immediate medical attention.
4. Measure:
Brake disc thickness a
Measure the brake disc thickness at a few different locations.
Out of specification Replace.
Brake disc thickness limit
3.0 mm (0.12 in)
EAS22240
5. Adjust:
Brake disc deflection
T.
R.
TIP
Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.
4-26
FRONT BRAKE
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
6. Install:
Front wheels
Refer to FRONT WHEELS on page 4-14.
EAS22250
TIP
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
T.
1. Measure:
Brake pad wear limit a
Out of specification Replace the brake
pads and brake pad spring as a set.
R.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
3. Install:
Brake pad holding bolt
Brake pad holding bolt plug
Brake caliper
T.
R.
4. Check:
Brake fluid level
Below the minimum level mark Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL on page 3-21.
5. Check:
Brake lever operation
Soft or spongy feeling Bleed the brake system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
2. Install:
Brake pad spring
Brake pads
EAS22310
TIP
4-27
FRONT BRAKE
TIP
If necessary
Brake hoses
Brake fluid
1. Check:
Brake caliper piston 1
Rust/scratches/wear Replace the brake
caliper piston.
Brake caliper cylinder 2
Scratches/wear Replace the brake caliper
assembly.
Brake caliper body 3
Cracks/damage Replace the brake caliper
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
3
1
Brake pads
WARNING
EWA28P1002
WARNING
EAS22410
EAS22390
EWA28P1003
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
4-28
FRONT BRAKE
Whenever a brake caliper is disassembled,
replace the brake caliper piston seal and
dust seal.
EWA13090
WARNING
Recommended fluid
DOT 4
EAS22440
ECA13540
NOTICE
T.
R.
3. Bleed:
Brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
4. Check:
Brake fluid level
Below the minimum level mark Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL on page 3-21.
5. Check:
Brake lever operation
Soft or spongy feeling Bleed the brake system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE
ROUTING on page 2-33.
ECA28P1014
NOTICE
EAS22500
3 New
4
2. Fill:
Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT 4
4-29
FRONT BRAKE
T.
4. Check:
Brake hoses
Cracks/damage/wear Replace.
R.
EWA13530
EAS22520
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE
ROUTING on page 2-33.
EWA28P1008
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components.
Whenever a master cylinder is disassembled, replace the brake master cylinder kit.
TIP
Recommended fluid
DOT 4
EAS22530
60
T.
R.
3. Install:
Front brake lever cover 1
TIP
Align the end of the brake master cylinder holder with the punch mark a on the handlebar.
Install the brake master cylinder holder with the
UP mark b facing up.
Install the brake master cylinder holder so that
the gaps between the brake master cylinder
and the brake master cylinder holder are
equal.
1
er
Low
UP
2. Install:
Brake hose
Copper washers New
Brake hose union bolt
4-30
FRONT BRAKE
c. Fit the hole b in the front brake lever cover
over the nut.
4. Fill:
Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT 4
EWA13540
WARNING
NOTICE
4-31
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
T.
R.
2
T.
R.
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear brake calipers.
Rear wheel
1
For installation, reverse the removal procedure.
4-32
REAR BRAKE
Removing the rear brake master cylinder
T.
R.
1
14
2
3
15
New 10
T.
R.
12
7
11
13
LS
.
R.
8
New
5
4
LS
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Drain.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
Brake fluid
1
Disconnect.
Disconnect.
Brake lever
Union bolt
10
Copper washer
11
Disconnect.
12
Disconnect.
13
14
4-33
REAR BRAKE
Removing the rear brake master cylinder
T.
R.
1
14
2
3
15
New 10
T.
R.
12
7
11
13
LS
.
R.
8
New
5
4
LS
T.
R.
Order
15
Job/Parts to remove
Qty
Remarks
1
For installation, reverse the removal procedure.
4-34
REAR BRAKE
Disassembling the rear brake master cylinder
3 New
2 New
1
Order
Job/Parts to remove
Qty
Dust boot
Circlip
Remarks
4-35
REAR BRAKE
Removing the rear brake calipers
T.
R.
T.
R.
T.
R.
1
2 New
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear brake calipers.
Drain.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
Brake fluid
Rear wheel
Union bolt
Copper washer
Disconnect.
Loosen.
4-36
REAR BRAKE
Disassembling the rear brake calipers
T.
R.
1
3
BF
T.
R.
S
S
New 7
4
New 6
5
S
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear brake calipers.
Brake pad
Bleed screw
1
For assembly, reverse the disassembly procedure.
4-37
REAR BRAKE
Refer to CHECKING THE FRONT BRAKE
DISCS on page 4-26.
EAS22560
INTRODUCTION
EWA14100
WARNING
T.
R.
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
Never disassemble brake components unless absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
Never use solvents on internal brake components.
Use only clean or new brake fluid for cleaning brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get immediate medical attention.
6. Install:
Rear wheels
Refer to REAR WHEELS on page 4-18.
EAS22580
EAS22570
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
Brake pad wear limit a
Out of specification Replace the brake
pads and brake pad spring as a set.
Brake pad lining thickness (inner)
5.8 mm (0.23 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
5.8 mm (0.23 in)
Limit
1.0 mm (0.04 in)
4-38
2. Install:
Brake pad spring
Brake pads
REAR BRAKE
EAS28P1004
TIP
ECA28P1006
NOTICE
The brake lever pivot bolt and nut have lefthanded threads. To loosen the pivot bolt and
nut, turn them clockwise.
EAS22600
1
2
TIP
1. Remove:
Brake caliper piston 1
Brake caliper dust seal 2
Brake caliper piston seal 3
T.
R.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
3. Install:
Brake pad holding bolt
Brake pad holding bolt plug
Brake caliper
3
1
T.
R.
4. Check:
Brake fluid level
Below the minimum level mark Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL on page 3-21.
5. Check:
Brake lever and pedal operation
Soft or spongy feeling Bleed the brake system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
4-39
EWA13550
WARNING
REAR BRAKE
3
1
b. Remove the brake caliper dust seal and
brake caliper piston seal.
EAS22650
EAS22640
EWA28P1003
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seal and
dust seal.
If necessary
Brake hoses
Brake fluid
Recommended fluid
DOT 4
INSTALLING THE REAR BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Install:
Brake caliper assembly
Brake caliper bolts 1
Brake hose 2
Copper washers 3 New
Brake hose union bolt 4
R.
EWA28P1002
EAS22670
T.
1. Check:
Brake caliper piston 1
Rust/scratches/wear Replace the brake
caliper piston.
Brake caliper cylinder 2
Scratches/wear Replace the brake caliper
assembly.
Brake caliper body 3
Cracks/damage Replace the brake caliper
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
WARNING
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE
ROUTING on page 2-33.
4-40
REAR BRAKE
5. Check:
Brake lever and pedal operation
Soft or spongy feeling Bleed the brake system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
ECA28P1014
NOTICE
EAS22710
2
1
4
New 3
a
1
2. Fill:
Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT 4
EWA13090
WARNING
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components.
Whenever a master cylinder is disassembled, replace the brake master cylinder kit.
NOTICE
Recommended fluid
DOT 4
EAS22750
R.
4-41
T.
3. Bleed:
Brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM on page 3-23.
4. Check:
Brake fluid level
Below the minimum level mark Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL on page 3-21.
REAR BRAKE
Brake lever
TIP
T.
Align the end of the brake master cylinder holder with the punch mark a on the handlebar.
Install the brake master cylinder holder with the
UP mark b facing up.
Install the brake master cylinder holder so that
the gaps between the brake master cylinder
and the brake master cylinder holder are
equal.
R.
ECA28P1007
NOTICE
The brake lever pivot bolt and nut have lefthanded threads. To tighten the pivot bolt and
nut, turn them counterclockwise.
4. Install:
Rear brake lever cover 1
TIP
a
2
b
1
2. Install:
Brake hose
Copper washers New
Brake hose union bolt
T.
R.
EWA13530
5. Fill:
Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE
ROUTING on page 2-33.
Recommended fluid
DOT 4
TIP
EWA13540
WARNING
60
3. Install:
Brake lever bracket
4-42
REAR BRAKE
ECA13540
NOTICE
4-43
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
T.
R.
14
14
8
9
11
13
15
7
12
10
13
4
2
T.
R.
Order
Job/Parts to remove
Qty
Handlebar cover
Plastic band
10
11
12
13
Handlebar grip
14
Handlebar holder
4-44
Remarks
Disconnect.
Disconnect.
HANDLEBAR
Removing the handlebar
T.
R.
14
14
8
9
11
13
15
7
12
10
13
4
2
T.
R.
Order
15
Job/Parts to remove
Qty
Handlebar
Remarks
1
For installation, reverse the removal procedure.
4-45
HANDLEBAR
EAS22860
EAS22880
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS22940
3. Install:
Handlebar grip 1
T.
R.
a. Wipe off grease or oil on the handlebar surface a with a lacquer thinner.
b. Apply a thin coat of rubber adhesive onto the
left and right ends of the handlebar.
c. Install the handlebar grips to the handlebar so
that arrow mark L faces up on the left handlebar grip and the arrow mark R faces up
on the right handlebar.
d. Wipe off any excess rubber adhesive with a
clean rag.
TIP
Install the handlebar within 15 from the horizontal line shown in the illustration.
The upper handlebar holders should be installed with the punch mark a forward A.
First tighten the bolts 1 on the front side of the
handlebar holders, and then tighten the bolts
2 on the rear side.
EWA13700
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
4-46
HANDLEBAR
Install the brake master cylinder holder so that
the gaps between the brake master cylinder
and the brake master cylinder holder are
equal.
1
er
Low
4. Install:
Left handlebar switch
Rear brake master cylinder 1
Rear brake master cylinder holder 2
6. Install:
Throttle lever assembly 1
Throttle lever assembly holder
T.
R.
TIP
TIP
Align the end of the brake master cylinder holder with the punch mark a on the handlebar.
The UP mark b on the brake master cylinder
holder should face up.
Install the brake master cylinder holder so that
the gaps between the brake master cylinder
and the brake master cylinder holder are
equal.
Align the projection a on the throttle lever assembly with the end of the brake master cylinder
holder b.
a
2
UP
5. Install:
Front brake master cylinder 1
Front brake master cylinder holder 2
T.
R.
TIP
Align the end of the brake master cylinder holder with the punch mark a on the handlebar.
The UP mark b on the brake master cylinder
holder should face up.
4-47
STEERING STEM
EAS29540
STEERING STEM
Removing the steering stem (for YFM5FG/YFM7FG)
T.
10
R.
T.
R.
LS
LS
5 New
New 1
16
LT
LT
5 New
LS
LS
New 12
T.
R.
New 14
LS
15
11
New
(4)
6
LT
LS
New 13
Job/Parts to remove
R.
R.
Order
T.
8
New
T.
7
25 Nm (2.5 m kg, 18 ft Ib)
Qty
Remarks
Handlebar
Lock washer
Cable guide
Collar
Oil seal
Tie-rod
Pitman arm
10
Steering stem
11
12
Oil seal
13
Oil seal
4-48
Disconnect.
STEERING STEM
Removing the steering stem (for YFM5FG/YFM7FG)
T.
10
R.
T.
R.
LS
LS
5 New
New 1
16
LT
LT
5 New
LS
LS
New 12
T.
R.
New 14
LS
15
11
New
(4)
6
LT
LS
New 13
Job/Parts to remove
R.
R.
Order
T.
8
New
T.
7
25 Nm (2.5 m kg, 18 ft Ib)
Qty
14
Circlip
15
Bearing
16
Remarks
4-49
STEERING STEM
Removing the steering stem (for YFM5FGP/YFM7FGP)
T.R
11
5 New
T.
R.
LS
New 1
LS
20
LS
LT
LT
5 New
LS
LT
14
.
T.R
T.
R.
13
15
12
17
10
35 Nm (3.5 m kg, 25 ft Ib)
18
T.R
16
10
T.
R.
New
LT
(4)
LT
19
Job/Parts to remove
R.
R.
R.
8
New
7
T.
9
T.
T.
Order
LT
LT
Qty
Remarks
Handlebar
Lock washer
Cable guide
Collar
Oil seal
Tie-rod
Pitman arm
10
11
Steering stem
12
Collar
13
Bearing nut
14
Collar
15
4-50
Disconnect.
STEERING STEM
Removing the steering stem (for YFM5FGP/YFM7FGP)
T.R
11
5 New
T.
R.
LS
New 1
LS
20
LS
LT
LT
5 New
LS
LT
14
.
T.R
T.
R.
13
15
12
17
10
35 Nm (3.5 m kg, 25 ft Ib)
18
T.R
16
10
T.
R.
New
LT
(4)
6
6
LT
19
Job/Parts to remove
R.
R.
R.
8
New
7
T.
9
T.
T.
Order
LT
LT
Qty
16
17
18
Remarks
ECA28P1008
19
EPS unit
20
NOTICE
The EPS unit should not be disassembled.
4-51
STEERING STEM
EAS29560
EAS28P1015
EWA15030
WARNING
11
10
18
UP
13
5
6
14
15
7 12 17
18
EAS29580
16
(4)
T.
R.
1. Install:
EPS unit 1
Washers
EPS unit bolts 2
TIP
T.
R.
2. Install:
Steering stem 3
Steering stem bearing 4
Collar 5
Bearing nut 6
a
T.
R.
Bearing nut
125 Nm (12.5 mkg, 90 ftlb)
TIP
4-52
STEERING STEM
Pass the cable and hoses through the cable
guide. Refer to CABLE ROUTING on page
2-33.
TIP
EAS28P1016
T.
R.
TIP
b
a
T.
R.
EAS29590
6. Tighten:
Steering stem bolts 13
T.
R.
TIP
T.
R.
4-53
STEERING STEM
TIP
4-54
R.
New
2
LS
New
T.
R.
T.
R.
12 New
T.
R.
11 New
New
T.
R.
10 New
7
New
8
9
LS
T.
R.
Order
Job/Parts to remove
Qty
Tie-rod
Nut
Nut
Steering knuckle
Circlip
Clip
Rubber boot
10
Ball joint
11
Circlip
12
Wheel bearing
1
For installation, reverse the removal procedure.
4-55
TIP
EWA15040
WARNING
EAS29680
ECA16190
NOTICE
EAS28P1030
EAS29690
4-56
3
1
c. Remove the ball joint 4.
TIP
90890-01474
YM-01474
Body
10
Installer spacer
11
Installer washer
12
Base
13
Guide bolt
14
Short bolt
90890-01480
YM-01480
90890-01514
YM-01514
13 9 11 7 8 12
14
13
a
4-57
10
a
1
a
b
EAS29700
T.
R.
Tie-rod nut
25 Nm (2.5 mkg, 18 ftlb)
TIP
2. Adjust:
Toe-in
Refer to ADJUSTING THE TOE-IN on page
3-29.
EAS28P1070
T.
R.
4-58
T.
R.
T.
R.
T.R
LS
13
13
17
New
9
3
10
10
14
16
15
LS
10
New
T.R
10
12
12
T.
R.
18
18
.R
.
R.
Job/Parts to remove
R.
R.
New
T.
T.
T.
11
Order
New
Qty
Nut
Nut
Nut/bolt
Nut/bolt
10
Nut/bolt
11
12
Dust cover
2/2
1
2/2
1
2/2
4-59
T.
R.
T.
R.
T.R
LS
13
13
17
New
9
3
LS
10
New
T.R
12
12
R.
T.
10
10
14
16
15
10
18
18
T
.R
.
R.
Job/Parts to remove
R.
R.
New
T.
T.
T.
11
Order
New
Qty
13
Bushing
14
Circlip
15
Clip
16
Rubber boot
17
Ball joint
18
Bushing
4-60
A
b. Check the front arm vertical movement B by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
2. Check:
Front upper arm
Front lower arm
Bends/damage Replace.
3. Check:
Bushings
Wear/damage Replace.
EAS29760
4-61
Long bolt
Body
Guide bolt
Remover attachment
Installer spacer
10
Installer washer
11
Base
90890-01474
YM-01474
90890-01480
YM-01480
EAS29790
6
7
5
7
8
4
12
11
TIP
T.
R.
4-62
T.
R.
a
1
a
b
T.
R.
6, 7
5
1
3, 4
8
6, 7
2
EAS28P1071
T.
R.
4-63
T.R
T.
R.
T.
R.
13
14
13
T.
12
14
15
12
LS
LS
8
9
R.
T.
T.
8
New 10
LS
.
T.R
11
7
R.
T.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear knuckles.
Plate
Rear knuckle
Spacer cover
Spacer
10
Circlip
11
Wheel bearing
12
Stabilizer joint
13
Stabilizer holder
4-64
T.R
T.
R.
T.
R.
13
14
13
T.
12
14
15
12
LS
LS
8
9
R.
T.
T.
8
New 10
LS
.
T.R
11
7
R.
T.
Order
Job/Parts to remove
Qty
14
Bushing
15
Stabilizer
Remarks
4-65
T.
R.
EWA15040
WARNING
NOTICE
EAS29820
4-66
R.
R.
T.
LS
7
4
7
6
4
10
LS
1
10
5
T.
R.
10
T.
R.
10
2
2
T.
R.
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear upper arms, rear lower arms, and
rear shock absorber assemblies.
Refer to REAR KNUCKLES AND STABILIZER on page 4-64
Rear knuckle/Stabilizer
1
Nut/Washer/Bolt
Nut/Bolt
Dust cover
Nut/Bolt
Dust cover
10
Bushing
2/1/2
1
2/2
2/2
4-67
EAS29850
EAS29870
A
b. Check the rear arm vertical movement B by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
B
B
T.
R.
2. Check:
Rear upper arm
Rear lower arm
Bends/damage Replace.
3. Check:
Bushings
Wear/damage Replace.
T.
R.
EAS29860
T.
R.
4-68
3, 4
1
8
6, 7
2
4-69
ENGINE
ENGINE REMOVAL ........................................................................................5-1
INSTALLING THE MUFFLER ...................................................................5-2
INSTALLING THE V-BELT COOLING DUCTS......................................... 5-2
INSTALLING THE DRIVE SELECT LEVER UNIT ....................................5-5
INSTALLING THE ENGINE....................................................................... 5-9
CYLINDER HEAD.......................................................................................... 5-10
REMOVING THE CYLINDER HEAD.......................................................5-12
CHECKING THE CYLINDER HEAD .......................................................5-12
CHECKING THE CAMSHAFT SPROCKET............................................5-13
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER .............................................................................. 5-13
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-13
INSTALLING THE CYLINDER HEAD .....................................................5-14
ROCKER ARMS AND CAMSHAFT ..............................................................5-17
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-18
CHECKING THE CAMSHAFT.................................................................5-18
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-19
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-19
VALVES AND VALVE SPRINGS.................................................................. 5-21
REMOVING THE VALVES...................................................................... 5-22
CHECKING THE VALVES AND VALVE GUIDES ..................................5-22
CHECKING THE VALVE SEATS ............................................................ 5-24
CHECKING THE VALVE SPRINGS........................................................ 5-25
INSTALLING THE VALVES .................................................................... 5-26
CYLINDER AND PISTON.............................................................................. 5-28
REMOVING THE PISTON ...................................................................... 5-29
CHECKING THE CYLINDER AND PISTON ...........................................5-29
CHECKING THE PISTON RINGS........................................................... 5-30
CHECKING THE PISTON PIN ................................................................5-31
INSTALLING THE PISTON AND CYLINDER .........................................5-32
AC MAGNETO AND STARTER CLUTCH ....................................................5-34
REMOVING THE AC MAGNETO ROTOR.............................................. 5-36
REMOVING THE STARTER CLUTCH ...................................................5-36
CHECKING THE STATOR COIL AND CRANKSHAFT
POSITION SENSOR .............................................................................. 5-37
CHECKING THE STARTER CLUTCH ....................................................5-37
CHECKING THE TORQUE LIMITER......................................................5-37
INSTALLING THE STARTER CLUTCH .................................................. 5-37
INSTALLING THE AC MAGNETO .......................................................... 5-38
TRANSMISSION............................................................................................ 5-73
REMOVING THE TRANSMISSION ........................................................ 5-76
CHECKING THE SHIFT FORKS............................................................. 5-76
CHECKING THE SHIFT DRUM ..............................................................5-76
CHECKING THE TRANSMISSION ......................................................... 5-76
CHECKING THE SECONDARY SHAFT................................................. 5-77
CHECKING THE STOPPER LEVER AND STOPPER WHEEL.............. 5-77
ASSEMBLING THE SHIFT FORK ASSEMBLY ...................................... 5-77
INSTALLING THE SHIFT FORKS AND SHIFT DRUM........................... 5-77
MIDDLE GEAR ..............................................................................................5-79
REMOVING THE MIDDLE DRIVE SHAFT ............................................. 5-82
REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-82
CHECKING THE PINION GEARS .......................................................... 5-83
INSTALLING THE BEARING AND OIL SEALS ...................................... 5-84
INSTALLING THE MIDDLE DRIVEN SHAFT .........................................5-84
INSTALLING THE MIDDLE DRIVE SHAFT ............................................5-85
MEASURING THE MIDDLE GEAR BACKLASH..................................... 5-86
ALIGNING THE MIDDLE GEAR ............................................................. 5-87
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the V-belt cooling ducts, muffler and exhaust pipe
T.
R.
T.
R.
5
7
6
10
9
11
6
New 8
New
T.
R.
4
3
1
2
Order
Job/Parts to remove
Qty
Remarks
Refer to GENERAL CHASSIS on page
4-1.
Spring
Muffler
Gasket
Muffler bracket
10
Exhaust pipe
11
Gasket
2
For installation, reverse the removal procedure.
5-1
ENGINE REMOVAL
EAS28P1023
Gaskets 1 New
Exhaust pipe 2
Exhaust pipe nuts 3
T.
R.
T.
R.
10
2
1
2. Install:
Muffler bracket 4
Muffler bracket bolts 5
10
3. Install:
Gasket 6 New
Muffler 7
Washer 8
Muffler bolt 9
TIP
EAS28P1024
TIP
10
10
5. Tighten:
Muffler bolt 9
T.
R.
Muffler bolt
20 Nm (2.0 mkg, 14 ftlb)
5-2
ENGINE REMOVAL
d,e
c
a
ab
1
2
e
c
2. Install:
V-belt cooling exhaust duct joint 1
V-belt cooling exhaust duct 2
5-3
ENGINE REMOVAL
Removing the drive select lever unit
T.
T.
R.
R.
R.
LS
LT
T.
R.
Order
Job/Parts to remove
Qty
Shift arm
Remarks
5-4
ENGINE REMOVAL
EAS28P1025
T.
R.
TIP
Make sure that the drive select lever and transmission are in N (neutral).
The installed length a of the shift rod is 413
mm (16.3 in).
N
2
a
3
N
5-5
ENGINE REMOVAL
Disconnecting the leads, cables and hoses
.
T.R
7
6
5
1
3
Order
Job/Parts to remove
Qty
Remarks
Coolant reservoir
Thermostat
Differential assembly
Starter motor
5-6
ENGINE REMOVAL
Disconnecting the leads, cables and hoses
.
T.R
7
6
5
1
3
Order
Job/Parts to remove
Qty
Remarks
Refer to PRIMARY AND SECONDARY
SHEAVES on page 5-47.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
AC magneto coupler
Disconnect.
Disconnect.
Disconnect.
5-7
ENGINE REMOVAL
Removing the engine
T.
R.
R.
LT
LT
T.
R.
6
8
5
7
LT
LT
9
6
R.
T.
R.
2
8
9
LT
T.
R.
R.
Order
Job/Parts to remove
Qty
ECA28P1024
NOTICE
4
Engine
TIP
Remove the engine from the left side of the
vehicle.
2
For installation, reverse the removal procedure.
5-8
ENGINE REMOVAL
EAS23720
T.
R.
ECA28P1025
NOTICE
8
4
5 3
1
3
2. Tighten:
Engine mounting bolts (front lower side) 2
Engine mounting bolts (front upper side) 3
Engine mounting bolts (rear lower side) 7
Engine mounting bolts (rear upper side) 8
Rubber damper nuts (front side) 9
Rubber damper nuts (rear side) 5
5-9
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
R.
R.
T.
T.
T.
R.
R.
T.
R.
T.
New
T.
R.
7 2
(4)
New
15
9
10
New
LS
New
New
LS
LS
14
6
(4)
12
13
11
New
LS
New
New
T.
R.
T.
R.
R.
R.
T.
New
T.
R.
R.
T.
Job/Parts to remove
Qty
R.
R.
R.
T.
T.
T.
Order
LS
Spark plug
Tappet cover
10
Gasket
11
Camshaft sprocket
12
Decompressor assembly
13
Cylinder head
5-10
Disconnect.
CYLINDER HEAD
Removing the cylinder head
R.
R.
T.
T.
T.
R.
R.
T.
R.
T.
T.
R.
7 2
New
(4)
New
15
9
10
New
LS
New
New
LS
LS
14
6
(4)
12
13
11
New
LS
New
New
T.
R.
T.
R.
R.
R.
T.
New
T.
R.
R.
T.
Job/Parts to remove
Qty
14
15
Dowel pin
R.
R.
R.
T.
T.
Order
LS
5-11
CYLINDER HEAD
4. Remove:
Timing chain tensioner
(along with the gasket)
Camshaft sprocket
Timing chain
EAS24130
TIP
5. Remove:
Cylinder head
TIP
b. When the piston is at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the stationary pointer d
on the cylinder head.
4
2
8
3
EAS24160
NOTICE
2. Loosen:
Camshaft sprocket bolts 1
Decompressor assembly bolts 2
TIP
2. Check:
Cylinder head
Damage/scratches Replace.
Cylinder head water jacket
Mineral deposits/rust Eliminate.
2
3. Loosen:
Timing chain tensioner cap bolt
5-12
CYLINDER HEAD
3. Measure:
Cylinder head warpage
Out of specification Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in)
a.
b.
1.
2.
1/4 tooth
Correct
Timing chain roller
Camshaft sprocket
EAS23940
1
2
EAS23960
EAS28P1026
5-13
CYLINDER HEAD
d. Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head.
e. Install the timing chain 2 onto the camshaft
sprocket 3, and then install the camshaft
sprocket onto the camshaft, and then finger
tighten the camshaft sprocket bolts 4.
EAS24230
T.
R.
d
c
TIP
NOTICE
2
8
TIP
5
2
3
1
4
7
4. Install:
Timing chain tensioner
3. Install:
Decompressor assembly
Camshaft sprocket
(onto the camshaft)
T.
R.
5-14
CYLINDER HEAD
TIP
T.
R.
6 New
d
3
2 New
c
1
7. Tighten:
Camshaft sprocket bolts 1
Decompressor assembly bolts 2
T.
R.
ECA13750
NOTICE
5. Turn:
Crankshaft
(several turns counterclockwise)
6. Check:
I mark a
Align the I mark on the AC magneto rotor
with the stationary pointer b on the AC magneto cover.
I mark c
Align the I mark on the camshaft sprocket
with the stationary pointer d on the cylinder
head.
Out of alignment Correct.
Refer to the installation steps above.
5-15
CYLINDER HEAD
8. Measure:
Valve clearance
Out of specification Adjust.
Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4.
5-16
R.
T.
R.
6
M
5
2
T.
5
6
4
E
10
T.
R.
1
E
E
E
Order
Job/Parts to remove
Qty
Cylinder head
LT
Remarks
Refer to CYLINDER HEAD on page 5-10.
Bearing retainer
Locknut
4
ECA28P1026
Camshaft
Decompressor lever
10
Bearing
NOTICE
Do not disassemble the camshaft assembly.
5-17
TIP
EAS23840
3. Measure:
Camshaft runout
Out of specification Replace the camshaft.
Camshaft runout limit
0.015 mm (0.0006 in)
5-18
EAS28P1028
4. Measure:
Rocker arm shaft outside diameter
Out of specification Replace.
1
2
5. Calculate:
Rocker-arm-to-rocker-arm-shaft clearance
Out of specification Replace the defective
part(s).
EAS23880
Rocker-arm-to-rocker-arm-shaft
clearance
0.0090.037 mm (0.00040.0015
in)
TIP
Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker
arm inside diameter.
EAS24040
5-19
TIP
Installed depth
0 mm (0 in)
1
a
5. Lubricate:
Rocker arms
Rocker arm shafts
Recommended lubricant
Rocker arm inner surface
Molybdenum disulfide grease
Rocker arm shaft
Engine oil
b. Installed depth
2. Lubricate:
Camshaft
Decompressor lever pin
Decompressor lever
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing, decompressor
lever pin, decompressor lever
Engine oil
6. Install:
Exhaust rocker arm 1
Exhaust rocker arm shaft 2
Intake rocker arm
Intake rocker arm shaft
TIP
3. Install:
Decompressor lever pin 1
Decompressor lever 2
TIP
Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as
shown in the illustration.
1
2
3
2
1
4. Install:
Camshaft 1
5-20
2
3
M
M
New
7
6
M
New
New
7
6
New
7
8
8
5
4
4
5
M
Order
Job/Parts to remove
Qty
Remarks
Cylinder head
Valve cotter
Valve spring
Exhaust valve
Intake valve
Valve guide
4
For installation, reverse the removal procedure.
5-21
3. Remove:
Valve spring retainer 1
Valve spring 2
Valve 3
Valve stem seal 4
Valve spring seat 5
TIP
TIP
EAS24290
2. Remove:
Valve cotters
TIP
5-22
2. Replace:
Valve guide
TIP
TIP
3. Eliminate:
Carbon deposits
(from the valve face and valve seat)
5-23
EAS24300
6. Measure:
Valve stem runout
Out of specification Replace the valve.
TIP
5-24
4. Lap:
Valve face
Valve seat
TIP
NOTICE
EAS24310
TIP
5-25
EAS24340
2. Measure:
Compressed valve spring force a
Out of specification Replace the valve
spring.
Installed compression spring
force (intake)
171.00197.00 N (17.4420.09
kgf, 38.4444.29 lbf)
Installed compression spring
force (exhaust)
171.00197.00 N (17.4420.09
kgf, 38.4444.29 lbf)
Installed length (intake)
35.00 mm (1.38 in)
Installed length (exhaust)
35.00 mm (1.38 in)
2. Lubricate:
Valve stem 1
Valve stem seal 2 New
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
b. Installed length
3. Measure:
Valve spring tilt a
Out of specification Replace the valve
spring.
3. Install:
Valve spring seat 1
Valve stem seal 2 New
5-26
NOTICE
b. Smaller pitch
4. Install:
Valve cotters
TIP
5-27
T.
R.
T.
R.
2
E
E
9
10
3 New
4
New 5
4
6
E
Order
New 5
Job/Parts to remove
Qty
Remarks
Cylinder head
Cylinder
Cylinder gasket
Dowel pin
Piston pin
Piston
Top ring
2nd ring
10
Oil ring
1
For installation, reverse the removal procedure.
5-28
TIP
ECA13810
NOTICE
EAS24400
3
TIP
2. Remove:
Top ring
2nd ring
Oil ring
5-29
Bore
92.00092.010 mm (3.6220
3.6224 in)
(YFM5FGY/YFM5FGPY)
102.000102.010 mm (4.0157
4.0161 in)
(YFM7FGY/YFM7FGPY)
Wear limit
92.080 mm (3.6252 in)
(YFM5FGY/YFM5FGPY)
102.080 mm (4.0189 in)
(YFM7FGY/YFM7FGPY)
Taper limit
0.05 mm (0.002 in)
Out of round limit
0.05 mm (0.002 in)
Piston-to-cylinder clearance
0.0300.055 mm (0.00120.0022
in)
Limit
0.10 mm (0.0039 in)
(YFM5FGY/YFM5FGPY)
0.13 mm (0.0051 in)
(YFM7FGY/YFM7FGPY)
f. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
C = maximum of D1D6
EAS24430
T = maximum of D1 or D2 - maximum of D5
or D6
R = maximum of D1, D3 or D5 - minimum of
D2, D4 or D6
b. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
c. Measure piston skirt diameter D a with the
micrometer.
TIP
Diameter D
91.95591.970 mm (3.6203
3.6209 in)
(YFM5FGY/YFM5FGPY)
101.955101.970 mm (4.0140
4.0146 in)
(YFM7FGY/YFM7FGPY)
5-30
TIP
3. Measure:
Piston pin bore diameter b
Out of specification Replace the piston.
a. 50 mm (1.97 in)
3. Measure:
Piston ring end gap
Out of specification Replace the piston
ring.
TIP
4. Calculate:
Piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston pin
and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b Piston pin outside diameter a
5-31
Piston-pin-to-piston-pin-bore
clearance
0.0040.024 mm (0.00020.0009
in)
Limit
0.0740 mm (0.0029 in)
Recommended lubricant
Engine oil
EAS24450
5. Offset:
Piston ring end gaps
120
TIP
120
120
90
d
45
a.
b.
c.
d.
e.
A.
45
Top ring
Oil ring expander
Upper oil ring rail
Lower oil ring rail
2nd ring
Exhaust side
6. Install:
Cylinder 1
Timing chain guide (exhaust side)
2. Install:
Piston 1
Piston pin 2
TIP
TIP
a
7. Install:
Cylinder bolts 1
2
3 New
TIP
Lubricate the cylinder bolt 1 threads and mating surface with engine oil.
3. Install:
Cylinder gasket New
5-32
T.
R.
Cylinder bolt
1st
15 Nm (1.5 mkg, 11 ftlb)
2nd
50 Nm (5.0 mkg, 36 ftlb)
Cylinder bolt (timing chain side)
10 Nm (1.0 mkg, 7.2 ftlb)
5-33
11
16
13
12
T.
R.
18
E
15
LT
10
LT
LT
7 17
New 6
New
9
8
14
T.
R.
LT
LT
LS
LT
R.
R.
T.R
T.R
T.
New
T.R
Order
R.
New
Job/Parts to remove
T.R
(10)
LT
T.
T.
LT
LT
Remarks
Engine oil
Drain.
Refer to CHANGING THE ENGINE OIL on
page 3-10.
Coolant
Drain.
Refer to CHANGING THE COOLANT on
page 3-17.
Water pump
AC magneto coupler
Disconnect.
Disconnect.
Lead holder
AC magneto cover
Dowel pin
Lead holder
5-34
11
16
13
12
T.
R.
18
E
15
LT
10
LT
LT
7 17
New 6
New
9
8
14
T.
R.
LT
LT
LS
LT
R.
R.
T.R
T.R
(10)
T.R
T.
New
T.R
Order
R.
New
Job/Parts to remove
LT
T.
T.
LT
LT
10
Stator coil
11
Torque limiter
12
13
14
AC magneto rotor
15
Starter clutch
16
Woodruff key
17
18
Washer
Remarks
5-35
ECA13880
NOTICE
TIP
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
TIP
2. Remove:
AC magneto rotor nut 1
Washer
TIP
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
TIP
3
2
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
3. Remove:
AC magneto rotor 1
(with the starter clutch)
Woodruff key
5-36
EAS28P1038
EAS28P1039
TIP
EAS24600
T.
R.
TIP
5-37
TIP
4. Tighten:
AC magneto rotor nut 1
EAS28P1068
T.
R.
T.
R.
TIP
TIP
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
3
b
2. Apply:
Sealant 1
(onto the crankshaft position sensor/stator
assembly lead grommet)
5. Install:
AC magneto cover
Lead holder 1
AC magneto cover bolts
T.
R.
TIP
3. Install:
Woodruff key
5-38
5-39
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
T.
R.
T.R
2
3
Order
Job/Parts to remove
Qty
Muffler
Remarks
Refer to ENGINE REMOVAL on page 5-1.
Disconnect.
Ground lead
Disconnect.
Starter motor
1
For installation, reverse the removal procedure.
5-40
ELECTRIC STARTER
Disassembling the starter motor
.
T.R
New
2
3
New
(4)
New
New
New
LS
New
4
LS
New
New
.
T.R
Order
Job/Parts to remove
Qty
Armature assembly
5-41
ELECTRIC STARTER
EAS24790
2
1
4. Measure:
Brush length a
Out of specification Replace the brushes
as a set.
TIP
3. Measure:
Armature assembly resistances (commutator
and insulation)
Out of specification Replace the starter
motor.
5. Measure:
Brush spring force
Out of specification Replace the brush
springs as a set.
Armature coil
Commutator resistance 1
0.00500.0150 at 20 C (68 F)
Insulation resistance 2
Above 1 M at 20 C (68 F)
b. If any resistance is out of specification, replace the starter motor.
6. Check:
Gear teeth
Damage/wear Replace the gear.
5-42
ELECTRIC STARTER
7. Check:
Bearing
Oil seal
Damage/wear Replace the defective
part(s).
EAS24800
Align the alignment marks a on the starter motor yoke with the match marks b on the front
and starter motor rear covers.
5-43
Order
Job/Parts to remove
Qty
Remarks
Refer to AC MAGNETO AND STARTER
CLUTCH on page 5-34.
Lock washer
Chain
Straight key
Lock washer
Plate
Spring
10
Pin
11
1
For installation, reverse the removal procedure.
5-44
3
4
2. Install:
Balancer drive gear 1
Balancer driven gear 2
Oil pump driven gear 3
5
1
TIP
EAS28P1042
EAS28P1043
3
3. Install:
Lock washers New
Oil pump driven gear nut 1
Balancer driven gear nut 2
T.
R.
EAS28P1044
TIP
TIP
5-45
5
2
3
1
4. Bend the lock washer tabs along the balancer
driven gear nut and oil pump driven gear nut.
5-46
R.
11 New
2 New
1
(11)
10 New
T.
R.
(8)
9
7
LS
4
New
T.
R.
T.
R.
Job/Parts to remove
Qty
R.
R.
T.
T.
Order
Rubber gasket
Bearing housing
Dowel pin
V-belt
10
Rubber gasket
11
Rubber gasket
1
For installation, reverse the removal procedure.
5-47
*
*
*
Order
Job/Parts to remove
Qty
Collar
Oil seal
O-ring
Remarks
5-48
Order
Job/Parts to remove
Qty
Nut
Spring seat
Compression spring
Spring seat
Guide pin
O-ring
Oil seal
Remarks
5-49
EAS28P1046
EAS24640
EAS24670
5-50
V-belt width
33.3 mm (1.31 in)
Limit
30.0 mm (1.18 in)
EAS24680
EAS24700
EAS24690
4. Check:
Secondary sheave spring
Damage Replace.
5. Measure:
Secondary sheave spring free length a
Out of specification Replace the secondary sheave spring.
5-51
2
a
1 New
1 New
2. Primary sliding sheave
3. Install:
Primary sheave weights 1
TIP
1 New
1 New
a
2. Install:
Oil seals 1 New
Installed depth a
0 mm (0 in)
2. Lubricate:
Secondary sliding sheave 1
5-52
6. Install:
Spring seat
Compression spring
Spring seat
Nut
Recommended lubricant
BEL-RAY assembly lube
TIP
Apply BEL-RAY assembly lube (15 g) to the inner surface of the secondary fixed sheave.
3. Install:
Secondary sliding sheave
4. Install:
Guide pins 1
T.
R.
Nut
90 Nm (9.0 mkg, 65 ftlb)
5. Lubricate:
Guide pin grooves 1
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
TIP
e. Remove the sheave spring compressor, locknut wrench, and sheave fixed block.
5-53
TIP
TIP
2
1
3
1
A. Correct position
B. Incorrect position
3. Tighten:
Primary sheave nut 1
Secondary sheave nut 2
T.
R.
TIP
5-54
5-55
CLUTCH
EAS25061
CLUTCH
Removing the clutch
Order
Job/Parts to remove
Qty
Remarks
Refer to PRIMARY AND SECONDARY
SHEAVES on page 5-47.
Gasket
Dowel pin
Nut
1
For installation, reverse the removal procedure.
5-56
CLUTCH
Disassembling the clutch housing assembly
Order
Job/Parts to remove
Qty
Oil seal
Circlip
Bearing housing
Circlip
Bearing
Circlip
Bearing
Clutch housing
Remarks
5-57
CLUTCH
One-way clutch bearing
Chafing/wear/damage Replace.
EAS25070
TIP
TIP
2. Check:
One-way clutch operation
2. Straighten:
Punched portion a of the nut 1
3. Remove:
Nut 1
ECA28P1032
NOTICE
The clutch carrier assembly nut has lefthanded threads. To loosen the clutch carrier
assembly nut, turn it clockwise.
TIP
EAS28990
2. Measure:
Clutch shoe thickness
Out of specification Replace.
Clutch shoe thickness
1.5 mm (0.06 in)
Limit
1.0 mm (0.04 in)
EAS28P1048
5-58
CLUTCH
T.
R.
ECA28P1033
NOTICE
The clutch carrier assembly nut has lefthanded threads. To tighten the clutch carrier
assembly nut, turn it counterclockwise.
TIP
EAS28P1037
Installed depth a
2.52.7 mm (0.100.11 in)
a
1
1 New
2. Clutch housing
2. Install:
TIP
Installed depth a
0 mm (0 in)
a
1 New
4. Install:
Dowel pins
2. Bearing housing
EAS28P1049
Gasket New
Clutch housing assembly
T.
Nut 1 New
R.
5-59
CLUTCH
TIP
5-60
CRANKCASE
EAS25540
CRANKCASE
Removing the timing chain and oil filter cartridge
T.
R.
R.
8 New
LS
T.
New
R.
T.
R.
LS
New
LS
5
T.
New
R.
LS
LT
LT
New
LT
New
LS
LT
LT
3
New
LT
T.
R.
New
LT
T.
R.
R.
Order
Job/Parts to remove
Qty
Engine
Cylinder head
Cylinder/Piston
Timing chain
Speed sensor
Dipstick
5-61
CRANKCASE
Removing the timing chain and oil filter cartridge
T.
R.
R.
8 New
LS
T.
New
R.
T.
R.
LS
New
LS
5
T.
New
R.
LS
LT
LT
New
LT
New
LS
LT
LT
3
New
LT
T.
R.
New
LT
T.
R.
R.
Order
Job/Parts to remove
Qty
Reverse switch
5-62
CRANKCASE
Separating the crankcase
T.
T.
R.
R.
T.
R.
New
E
9
6
T.
R.
2 New
New
(4)
New
LS
10
E
LS
T.
R.
Job/Parts to remove
Qty
R.
R.
T.
T.
Order
Gasket
Dowel pin
Shift lever 1
Right crankcase
Dowel pin
10
Left crankcase
1
For assembly, reverse the disassembly procedure.
5-63
CRANKCASE
Removing the crankcase bearings
New
LS
LS
LT
LT
New 3
T.
R.
LT
.
7
6
7
7
E
7
E
Order
Job/Parts to remove
Qty
Remarks
Crankshaft/Oil pump
Transmission
Collar
O-ring
Oil seal
Bearing retainer
Spacer
Crank seal
Bearing
9
For installation, reverse the removal procedure.
5-64
CRANKCASE
EAS25560
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
A
2. Check:
Timing chain guide (intake side)
Damage/wear Replace.
EAS28P1050
4
3
2
1
A. Left crankcase
B. Right crankcase
2. Remove:
Right crankcase
Dowel pins
EAS28P1051
ECA13900
NOTICE
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves separate evenly.
EAS24180
5-65
CRANKCASE
EAS25580
2
2
5. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft hammer.
EAS25700
ECA28P1034
NOTICE
Installed depth a
1.01.5 mm (0.040.06 in)
1 New
6. Install:
Lead holders
Crankcase bolts
7. Tighten:
Crankcase bolts
T.
R.
2. Crankcase
Crankcase bolt 1
26 Nm (2.6 mkg, 19 ftlb)
Crankcase bolt 2, 3
10 Nm (1.0 mkg, 7.2 ftlb)
M8 40 mm 1
M6 60 mm 2
M6 30 mm 3
TIP
5-66
CRANKCASE
2
3
2
3
1
2
A. Right crankcase
B. Left crankcase
8. Apply:
4-stroke engine oil
(to the crankshaft pin, bearings and oil delivery hole)
9. Check:
Crankshaft and transmission operation
Rough operation Repair.
EAS28P1052
T.
R.
TIP
5-67
4
2 New
1
T.
R.
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Separate.
Refer to CRANKCASE on page 5-61.
Crankcase
1
Oil pump
Gasket
Balancer
Crankshaft
1
For installation, reverse the removal procedure.
5-68
6
3
2
5
4
1
E
T.
R.
Order
Job/Parts to remove
Qty
Pin
Inner rotor
Outer rotor
Remarks
5-69
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.12 mm (0.0047 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.0900.170 mm (0.00350.0067
in)
Limit
0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-andouter-rotor clearance
0.030.10 mm (0.00120.0039 in)
Limit
0.17 mm (0.0067 in)
TIP
NOTICE
2
1
EAS24960
1. Inner rotor
2. Outer rotor
3. Oil pump housing
3. Check:
Oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the defective part(s).
5-70
c
b
EAS24990
4. Check:
Crankshaft sprocket
Damage/wear Replace the crankshaft.
Bearing
Cracks/damage/wear Replace the crankshaft.
5. Check:
Crankshaft journal
Scratches/wear Replace the crankshaft.
Crankshaft journal oil passage
Obstruction Blow out with compressed air.
Width A
74.9575.00 mm (2.9512.953 in)
2. Measure:
Crankshaft runout C b
Out of specification Replace the crankshaft.
Runout limit C
0.030 mm (0.0012 in)
EAS25010
3. Measure:
Big end side clearance D c
Out of specification Replace the crankshaft.
Big end side clearance D
0.3500.650 mm (0.01380.0256
in)
Recommended lubricant
Engine oil
2. Install:
Oil pump housing 1
Outer rotor 2
Inner rotor 3
Oil pump shaft 4
Pin 5
TIP
5-71
2
5
4
5
3. Check:
Oil pump operation
Refer to CHECKING THE OIL PUMP on
page 5-70.
ECA28P1035
NOTICE
EAS28P1056
TIP
TIP
Install the crankshaft assembly with the crankshaft installer pot 2, crankshaft installer bolt 3,
adapter (M16) 4, spacer (crankshaft installer)
5 and spacer 6.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Spacer
90890-01309
Pot spacer
YU-90059
5-72
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum and shift forks
E
1
12
11
New
7
New
M
10
6
New
New
4
8
3
New
E
2
Order
Job/Parts to remove
Qty
Remarks
Crankcase
Separate.
Refer to CRANKCASE on page 5-61
Shift drum
Shift fork R
Spring
Shift fork L
Secondary shaft
10
11
Stopper lever
12
1
For installation, reverse the removal procedure.
5-73
TRANSMISSION
Disassembling the drive axle assembly
9
8
New 6
5
4
3
1
17
18
16
M
M
15
14
12
10
Order
13 New
11 New
Job/Parts to remove
Qty
Washer
Collar
Washer
Clutch dog
Circlip
Washer
Collar
10
Washer
11
Circlip
12
13
Circlip
14
Washer
15
Bearing
16
17
Stopper wheel
5-74
Remarks
TRANSMISSION
Disassembling the drive axle assembly
9
8
New 6
5
4
3
1
17
18
16
M
M
15
14
12
10
Order
18
13 New
11 New
Job/Parts to remove
Qty
Drive axle
Remarks
1
For assembly, reverse the disassembly procedure.
5-75
TRANSMISSION
EAS26250
3. Check:
Shift fork movement
(along the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
EAS26260
4. Check:
Spring
Cracks/damage Replace.
EAS28P1057
2. Check:
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
EAS26300
EWA12840
WARNING
5-76
TRANSMISSION
Stopper wheel 2
Damage/wear Replace the stopper wheel
and stopper lever as a set.
Stopper lever shaft 3
Bends/damage/wear Replace.
2. Check:
Transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(s).
Transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(s).
EAS28P1060
New 5
1
2
3
28P
b
New 5
a
4
EAS28P1061
EAS28P1058
5-77
TRANSMISSION
3
2
4
5
TIP
2. Check:
Shift operation
Rough operation Repair.
TIP
5-78
MIDDLE GEAR
EAS25710
MIDDLE GEAR
Removing the middle drive shaft
T.R
LT
LT
LT
New
New
LT
LT
Order
LT
LT
Job/Parts to remove
Qty
Remarks
Separate.
Refer to CRANKCASE on page 5-61.
Crankcase
1
Bearing housing
Bearing retainer
Bearing
Circlip
5-79
MIDDLE GEAR
Removing the middle driven shaft
Order
Job/Parts to remove
Qty
Remarks
Separate.
Refer to CRANKCASE on page 5-61.
Crankcase
1
Bearing housing
O-ring
10
Bearing
11
12
Bearing
13
14
Bearing
5-80
MIDDLE GEAR
Removing the middle driven shaft
Order
15
Job/Parts to remove
Qty
Remarks
1
For installation, reverse the removal procedure.
5-81
MIDDLE GEAR
EAS28P1062
TIP
1
3
2. Remove:
Rear drive shaft yoke nut (middle gear side)
1
Washer
Rear drive shaft yoke (middle gear side) 2
3. Remove:
Middle drive pinion gear nut
Middle drive pinion gear
Shim(s)
4. Remove:
Middle driven gear 1
Circlip
Middle drive shaft 2
TIP
TIP
2
1
1
3
3. Remove:
Bearing housing assembly 1
EAS28P1063
ECA28P1036
NOTICE
Never directly press the middle driven pinion gear end with a hydraulic press, this will
result in damage to the middle driven pinion gear thread.
TIP
5-82
MIDDLE GEAR
Install a suitable socket 2 on the middle
driven pinion gear end to protect the thread
from damage.
ECA28P1038
NOTICE
4. Remove:
Middle driven pinion gear bearing retainer
Bearing
ECA28P1037
NOTICE
The middle driven pinion gear bearing retainer has left-handed threads. To loosen the retainer, turn it clockwise.
6. Remove:
Middle driven shaft 1
(with bearing)
1
2
1
EAS28P1064
5. Remove:
Oil seal 1
Middle driven shaft bearing retainer 2
TIP
5-83
MIDDLE GEAR
Bearings
Pitting/damage Replace.
EAS28P1065
ECA28P1039
NOTICE
1
5
4
2 New
b
3 New
c
6
2
2. Install:
Middle driven pinion gear bearing retainer 1
4.
5.
6.
7.
EAS28P1066
T.
R.
T.
R.
Bearing retainer
130 Nm (13.0 mkg, 94 ftlb)
LOCTITE
ECA28P1040
NOTICE
The middle driven pinion gear bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise.
TIP
5-84
MIDDLE GEAR
1
1
2
2
3
5. Install:
Front drive shaft yoke (middle gear side) 1
Washer
Front drive shaft yoke nut (middle gear side)
2
3. Install:
Middle driven pinion gear shim(s) 1
Bearing housing
TIP
T.
R.
TIP
1
4. Install:
Rear drive shaft yoke (middle gear side) 1
Washer
Rear drive shaft yoke nut (middle gear side)
2
T.
R.
2
3
TIP
EAS28P1067
5-85
MIDDLE GEAR
EAS25890
1
2. Tighten:
T.
R.
TIP
4
3
3
a
b. 45 mm (1.8 in)
d. Measure the gear lash while rotating the middle driven shaft back and forth.
TIP
5-86
MIDDLE GEAR
e. If the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shims
and/or middle drive pinion gear shim(s).
a. Position the middle gears with the appropriate shim(s) that has had its respective thickness calculated from information marked on
the crankcase, middle driven shaft bearing
housing and middle driven pinion gear.
b. To find middle drive pinion gear shim thickness A, use the following formula.
Middle drive pinion gear shim thickness
A = e + d - b - c - a
EAS25930
1. Select:
Middle drive pinion gear shim(s) 1
Middle driven pinion gear shim(s) 2
a
b is 17.0
c is 55.0
If the right crankcase is marked 64.97,
d is 64.97
5-87
MIDDLE GEAR
Therefore, A is 1.40.
A = 9.01 + 64.97 - 17.0 - 55.0 - 0.58 = 1.40
Round off hundredths digit and select appropriate shim(s).
In the above example, the calculated shim
thickness is 1.40 mm. The following chart instructs you, however, to round off 0 to 0.
Hundredth
Rounded value
0, 1, 2
3, 4, 5, 6, 7
8, 9
10
c. To find middle driven pinion gear shim thickness B, use the following formula.
Middle driven pinion gear shim thickness
B = f - g + h - i - j - 0.05
f = a numeral (usually a decimal number) on
the bearing housing is either added to or subtracted from 77.5
TIP
After replacing any part in the middle driven pinion gear assembly, the overall length of the assembly will change. Therefore, be sure to
measure distance f to select the correct middle
driven pinion gear shim thickness.
5-88
MIDDLE GEAR
Middle driven pinion gear shim
Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 0.60
h
If the left crankcase is marked 99.99,
i is 99.99
Therefore, B is 0.72.
B = 77.53 - 49.0 + 80.40 - 99.99 - 8.17 - 0.05
= 0.72
Round off hundredth digit and select appropriate shim(s).
In the example above, the calculated shim
thickness is 0.72 mm. The chart instructs
you, however, to round off 2 to 0.
Hundredth
Rounded value
0, 1, 2
3, 4, 5, 6, 7
8, 9
10
5-89
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR..................................................................6-3
THERMOSTAT ................................................................................................6-4
CHECKING THE THERMOSTAT.............................................................. 6-5
INSTALLING THE THERMOSTAT............................................................ 6-5
WATER PUMP.................................................................................................6-7
DISASSEMBLING THE WATER PUMP.................................................... 6-9
CHECKING THE WATER PUMP .............................................................. 6-9
ASSEMBLING THE WATER PUMP.......................................................... 6-9
RADIATOR
EAS26380
RADIATOR
Removing the radiator
(4)
1
8
11
10
7
R.
R.
Order
T.
T.
Job/Parts to remove
Qty
Remarks
Coolant
Drain.
Refer to CHANGING THE COOLANT on
page 3-17.
Coolant reservoir
Radiator bracket
10
Radiator
6-1
Disconnect.
RADIATOR
Removing the radiator
(4)
1
8
11
10
11
R.
R.
Order
T.
T.
Job/Parts to remove
Qty
Radiator fan
Remarks
1
For installation, reverse the removal procedure.
6-2
RADIATOR
EAS26390
4. Check:
Radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to COOLING SYSTEM on page 9-27.
EAS26400
2. Check:
Radiator hoses
Cracks/damage Replace.
3. Measure:
Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Radiator cap opening pressure
93.3122.7 kPa (0.951.25
kgf/cm, 13.517.8 psi)
6-3
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat
4
5
1
New
T.
R.
T.
R.
2
New
LS
New
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Coolant
Drain.
Refer to CHANGING THE COOLANT on
page 3-17.
Thermostat cover
Thermostat
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-4
THERMOSTAT
2. Check:
Thermostat housing cover
Thermostat housing (cylinder head)
Cracks/damage Replace.
EAS26450
EAS26480
T.
R.
ECA28P1016
NOTICE
2. Install:
Thermostat 1
O-ring 2 New
Thermostat cover 3
T.
R.
TIP
3
2
New
LS
3. Fill:
Cooling system
(with the specified amount of the recommended coolant)
Refer to CHANGING THE COOLANT on
page 3-17.
4. Check:
Cooling system
Leaks Repair or replace any faulty part.
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
6-5
THERMOSTAT
5. Measure:
Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to CHECKING THE RADIATOR on
page 6-3.
6-6
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
LS
12 New
11
5
10 New
8 New
7 New
New
New
1
LS
6
3
T.
R.
4
New
R.
R.
Job/Parts to remove
T.
T.
Order
LS
Qty
Remarks
AC magneto cover
Coolant
Drain.
Refer to CHANGING THE COOLANT on
page 3-17.
Gasket
Circlip
Impeller shaft
10
6-7
Disconnect.
WATER PUMP
Removing the water pump
LS
12 New
11
5
10 New
8 New
7 New
New
New
1
LS
6
3
T.
R.
4
New
R.
R.
Job/Parts to remove
T.
T.
Order
Qty
11
Bearing
12
Oil seal
LS
Remarks
6-8
WATER PUMP
EAS26510
EAS26560
TIP
TIP
2. Remove:
Bearing 1
Oil seal 2
TIP
Remove the bearing and oil seal from the outside of the AC magneto cover 3.
1 New
2. Install:
1
2
ECA14080
NOTICE
6-9
WATER PUMP
A
4
1 New
2
3. Mechanical seal installer
4. Middle driven shaft bearing driver
A. Push down.
3. Measure:
Impeller shaft tilt
Out of specification Replace.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1. Straightedge
2. Impeller
4. Install:
Impeller shaft 1
Circlip New
TIP
6-10
WATER PUMP
6-11
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1
REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
CHECKING THE FUEL TANK BREATHER HOSE JOINT .......................7-2
INSTALLING THE FUEL PUMP................................................................7-2
INSTALLING THE FUEL TANK.................................................................7-3
THROTTLE BODY........................................................................................... 7-4
REMOVING THE THROTTLE BODY ASSEMBLY ...................................7-6
CHECKING THE INJECTOR .................................................................... 7-6
CHECKING THE THROTTLE BODY ........................................................7-6
INSTALLING THE THROTTLE BODY ASSEMBLY..................................7-6
CHECKING THE FUEL PRESSURE ........................................................7-7
ADJUSTING THE THROTTLE POSITION SENSOR................................7-7
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
T.
(6)
R.
4
.
T.R
(4)
New
8
11
5
7
12
1
10
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Refer to GENERAL CHASSIS on page
4-1.
Rear fender
1
Fuel hose
Fuel tank
10
11
12
Damper
Disconnect.
Disconnect.
7-1
FUEL TANK
EAS26630
TIP
ECA28P1019
NOTICE
ECA14720
NOTICE
TIP
EAS26670
T.
R.
TIP
3. Remove:
Fuel tank
7-2
FUEL TANK
EAS28P1021
1
1
2. Install:
Fuel hose
Fuel hose connector holder 1
Fuel pump coupler
ECA28P1020
NOTICE
Install the fuel hose connector holder 1 securely onto the fuel pump until a distinct click
is heard, and then make sure that it does not
come loose.
To install the fuel hose onto the throttle body,
slide the fuel hose connector cover 2 on the
end of the hose in direction of the arrow shown.
7-3
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
LS
New 4
8
5
10
3
11
7
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Refer to GENERAL CHASSIS on page
4-1.
Disconnect.
Disconnect.
Throttle cable
Disconnect.
Loosen.
Fuel hose
Disconnect.
Disconnect.
10
11
Disconnect.
7-4
THROTTLE BODY
Disassembling the throttle body assembly
3
4
1
LS
New
New
2
5
Order
Job/Parts to remove
Qty
Fuel injector
Remarks
ECA28P1021
Throttle body
NOTICE
The throttle body should not be disassembled.
For assembly, reverse the disassembly procedure.
7-5
THROTTLE BODY
b. Blow out all of the passages with compressed
air.
EAS28P1036
EAS28P1022
ECA28P1022
NOTICE
TIP
TIP
2. Install:
Throttle body assembly 1
TIP
Align the projection a on the throttle body assembly with the slot b in the throttle body joint.
1
a
EAS26980
b
3. Connect:
Fuel hose
EAS26990
ECA28P1023
TIP
NOTICE
7-6
THROTTLE BODY
EAS27010
Fuel pressure
324 kPa (3.24 kgf/cm, 46.1 psi)
EAS27030
TIP
L Y B/L
7-7
THROTTLE BODY
c. Turn the main switch to ON.
d. Measure the throttle position sensor voltage.
e. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
Throttle position sensor output
voltage
0.630.73 V (yellowblack/blue)
f. After adjusting the throttle position sensor angle, tighten the throttle position sensor
screws 3.
7-8
THROTTLE BODY
7-9
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................8-1
CHECKING NOISES ................................................................................. 8-1
TROUBLESHOOTING CHART .................................................................8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL
ASSEMBLY AND FRONT DRIVE SHAFT .....................................................8-3
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ........................................................................................... 8-9
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ........................................................................................... 8-9
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 8-11
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-11
CHECKING THE DIFFERENTIAL MOTOR ............................................8-11
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ..................................8-12
MEASURING THE DIFFERENTIAL GEAR BACKLASH......................... 8-13
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-13
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-15
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-22
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-22
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-23
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY....... 8-24
CHECKING THE REAR DRIVE SHAFT.................................................. 8-24
CHECKING THE FINAL DRIVE ASSEMBLY..........................................8-24
ASSEMBLING THE FINAL DRIVE CASE ............................................... 8-25
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY............. 8-25
SELECTING THE FINAL DRIVE PINION GEAR SHIM(S) .....................8-25
SELECTING THE FINAL DRIVEN PINION GEAR SHIM
(FINAL DRIVE CASE SIDE) AND THRUST WASHER .......................... 8-26
SELECTING THE FINAL DRIVEN PINION GEAR SHIM
(FINAL DRIVE CASE COVER SIDE) .....................................................8-28
SELECTING THE WHEEL GEAR SHIM(S) ............................................8-28
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-29
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-30
TROUBLESHOOTING
EAS29890
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms
Possible Causes
A. Bearing damage.
B. Improper gear backlash.
C. Gear tooth damage.
D. Broken drive shaft.
E. Broken gear teeth.
F. Seizure due to lack of lubrication.
G. Small foreign objects lodged between the
moving parts.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
EAS29900
EWA13790
CHECKING NOISES
1. Investigate any unusual noises.
WARNING
2. Check:
Drained oil
Drained oil shows large amounts of metal
particles Check the bearing for seizure.
TIP
EWA13780
WARNING
Insufficient gear backlash is extremely destructive to the gear teeth. If a test ride, following reassembly, indicates these
symptoms, stop riding immediately to minimize gear damage.
c. A slight thunk evident at low speed operation. This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
TIP
An apparent oil leak on a new or nearly new vehicle may be the result of a rust-preventative
coating or excessive seal lubrication.
8-1
TROUBLESHOOTING
Always clean the vehicle and recheck the suspected location of an apparent leakage.
EAS29910
TROUBLESHOOTING CHART
When basic conditions (a) and (b) exist, check the following points:
1. Elevate and spin both wheels. Feel
for wheel bearing damage.
YES
NO
NO
Constant velocity shaft bearings and differential bearings are probably not damaged.
Repeat the test or remove the individual
components.
NO
NO
NO
2. Check the wheel nuts and axle nuts
for tightness.
YES
3. Check the front constant velocity
shaft assemblies. Feel for bearing
damage.
YES
4. Check the rear brake adjustment.
YES
5. Check the rear constant velocity
shaft assemblies. Feel for bearing
damage.
YES
Remove the shaft drive components.
8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS29920
T.
R.
LT
1
LS
New
8
New
10
LT
LT
LS
LS
LS
LS
T.
R.
Order
Job/Parts to remove
Qty
Steering knuckles
Front arms
Drain.
Refer to CHANGING THE DIFFERENTIAL
GEAR OIL on page 3-27.
Disconnect.
Disconnect.
Differential assembly
Spring
Damper
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft
T.
R.
LT
1
LS
New
8
New
10
LT
LT
LS
LS
LS
LS
T.
R.
Order
Job/Parts to remove
Qty
Dust seal
10
Dust seal
8-4
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the front constant velocity shaft assemblies
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the front constant velocity shaft assemblies.
Clip
Boot band
Boot band
Dust boot
Clip
Circlip
Ball bearing
Boot band
10
Boot band
11
Dust boot
12
13
Clip
8-5
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the front constant velocity shaft assemblies
Order
14
Job/Parts to remove
Qty
Remarks
1
For assembly, reverse the disassembly procedure.
A: Wheel side
B: Differential side
8-6
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
T.
R.
T.
R.
12
14
13
15
New
11
LS
T.
(5)
R.
16
17
LS
New
10
7
T.
R.
T.
R.
LT
New
1
2
9
LS
New
8
6
LS
New
Order
New
16
Job/Parts to remove
Qty
Remarks
TIP
Do not disassemble the differential motor or
remove the differential motor pinion gear.
1
Differential motor
O-ring
O-ring
Bearing
10
Bearing
11
Oil seal
12
Clip
13
14
Bearing
8-7
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
T.
R.
T.
R.
12
14
15
New
11
13
LS
T.
(5)
R.
16
17
LS
New
10
7
T.
R.
T.
R.
LT
New
1
5
9
LS
New
8
6
LS
New
Order
16
Job/Parts to remove
Qty
15
Bearing
16
Oil seal
17
Differential case
New
Remarks
8-8
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS29930
TIP
3. Remove:
Dust boot
Constant velocity joint
Clip
2
1
B. Wheel side
TIP
1
A
4
3
B. Wheel side
EAS29960
A. Differential side
2. Remove:
Boot band 1
Use the boot band installation tool 2.
Boots band installation tool
90890-01526
YM-01526
ECA28P1042
NOTICE
8-9
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Ball bearing 1
EAS29990
Circlip 2 New
Double offset joint 3
Clip 4 New
TIP
Clip 1 New
Constant velocity joint 2
Constant velocity shaft 3
Dust boot
TIP
2 New
New 1
3
A
4 New
B. Differential side
3. Apply:
Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
New 1
2
A
TIP
The new boot bands may differ from the original ones.
2. Install:
Dust boot
8-10
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
The dust boots should be fastened with the
boot bands 3 and 5 at the grooves in the
constant velocity shaft.
ECA16200
NOTICE
The ring gear and differential gear are assembled into a proper unit at the factory by
means of specialized equipment. Do not attempt to disassemble this unit. Disassembly
will result in the malfunction of the unit.
EAS29970
6
4
5. Check:
Thrust movement free play
Excessive play Replace the constant velocity shaft assembly.
EWA15060
WARNING
NOTICE
EAS29950
8-11
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
a. Connect two C-size batteries to the differential motor terminals 1 (as shown in the illustrations).
ECA28P1018
NOTICE
3V
b. Connect two C-size batteries to the differential motor terminal 2 to operate the differential motor pinion gear 3. Operate the
differential motor pinion gear until the mark
4 on the differential motor pinion gear is
aligned with the mark 5 on the differential
motor case.
ECA16230
NOTICE
3V
3V
3
4
5
2
c. Insert 6 mm bolts 6 into the differential motor 7 and use them as a guide to set the motor on the differential case cover 8 so that
the shift fork sliding gear 9 does not move.
1
A. Check that the differential motor pinion gear
2 turns counterclockwise.
B. Check that the differential motor pinion gear
2 turns clockwise.
ECA16240
NOTICE
EAS30000
6
7
a. Slide the shift fork sliding gear 1, which is installed to the differential case cover, to the left
as shown in the illustration to put it into the
2WD mode.
8-12
6
9
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
d. Remove the 6 mm bolts, and then install the
motor with the differential motor bolts.
T.
R.
3. Check:
Differential assembly operation
Unsmooth operation Replace the differential assembly.
Insert the double offset joint into the differential assembly, and turn the gears back and
forth.
5. Measure:
Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash
0.050.25 mm (0.0020.010 in)
TIP
Measure the gear backlash at four positions. Rotate the differential pinion gear 90 each time.
EAS30030
EAS30020
2. Adjust:
Gear backlash
NOTICE
4. Attach:
Gear lash measurement tool 2
Dial gauge 3
Thicker shim
8-13
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
b. Measure the differential gear backlash again.
8-14
T.
R.
LS
LS
6
5
10 9
New
8
New
T.
R.
Order
Job/Parts to remove
Qty
Remarks
Rear arms
Drain.
Refer to CHANGING THE FINAL GEAR
OIL on page 3-26
Trailer hitch
Spring
Damper
Dust seal
8-15
Disconnect.
T.
R.
LS
LS
6
5
10 9
New
8
New
T.
R.
Order
10
Job/Parts to remove
Qty
Dust seal
Remarks
1
For installation, reverse the removal procedure.
8-16
Order
Job/Parts to remove
Qty
Remarks
The following procedure applies to both of
the rear constant velocity shaft assemblies.
Clip
Boot band
Boot band
Dust boot
Clip
Circlip
Ball bearing
Boot band
10
Boot band
11
Dust boot
12
13
Clip
8-17
Order
14
Job/Parts to remove
Qty
Remarks
1
For assembly, reverse the disassembly procedure.
A: Wheel side
B: Final drive side
8-18
23
28
New
29
R.
25
27
T.
T.
R.
(4)
R.
20
21
New 24
22
26
16 New
LT
LS
New
4
17
New
19
10
LS
LS
18
New
15
6 New
14
13
T.
R.
12
11
T.
R.
Job/Parts to remove
(11)
8
New 5
Order
Qty
LS
Remarks
1
Refer to SELECTING THE FINAL DRIVE
PINION GEAR SHIM(S) on page 8-25.
TIP
3
Dowel pin
Gasket
Oil seal
Bearing
Bearing
10
Wheel gear
11
12
Pinion gear
8-19
23
28
New
29
R.
25
27
T.
T.
R.
(4)
R.
20
21
New 24
22
26
16 New
LT
LS
New
4
17
New
19
10
LS
LS
18
New
15
6 New
14
13
T.
R.
12
G
T.
R.
Order
13
Job/Parts to remove
(11)
8
New 5
Qty
11
LS
Remarks
14
Thrust washer
15
16
Oil seal
17
Bearing
18
Bearing
19
20
21
Washer
22
23
24
Oil seal
25
Bearing
8-20
23
28
New
29
R.
25
27
T.
T.
R.
(4)
R.
20
21
New 24
22
26
16 New
LT
LS
New
4
17
New
19
10
LS
LS
18
New
15
6 New
14
13
T.
R.
12
G
T.
R.
Order
Job/Parts to remove
Expander
27
Washer
28
Bearing
29
(11)
8
New 5
Qty
26
11
LS
Remarks
8-21
TIP
3. Remove:
Dust boot
Constant velocity joint
Clip
2
1
B. Wheel side
TIP
1
A
4
3
B. Wheel side
EAS30330
2. Remove:
Boot band 1
Use the boot band installation tool 2.
Boots band installation tool
90890-01526
YM-01526
ECA16210
NOTICE
8-22
EAS30070
Circlip 2 New
Double offset joint 3
Clip 4 New
TIP
Clip 1 New
Constant velocity joint 2
Constant velocity shaft 3
Dust boot
TIP
2 New
New 1
3
A
4 New
3. Apply:
Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
New 1
2
A
TIP
The new boot bands may differ from the original ones.
2. Install:
Dust boot
8-23
EAS30150
EAS30160
6
4
TIP
5. Check:
Thrust movement free play
Excessive play Replace the constant velocity shaft assembly.
2. Check:
Gear teeth
Pitting/galling/wear Replace the final drive
pinion gear and final driven pinion gear as a
set.
TIP
When the final drive pinion gear, final driven pinion gear and/or wheel gear are replaced, be sure
to adjust the shim of the final drive pinion gear,
final driven pinion gear and/or wheel gear.
Oil seals
O-ring
Damage Replace.
3. Check:
Bearings
Damage Replace.
EAS28P1017
8-24
EAS28P1019
TIP
EAS28P1020
2. Check:
Final drive assembly operation
Unsmooth operation Replace the final
drive assembly.
Insert the double offset joint into the final
drive assembly, and turn the gears back and
forth.
EAS30110
T.
a. To find the final drive pinion gear shim thickness A, use the following formula.
Final drive pinion gear shim thickness
A = a + (c - b) - d
R.
a = 55 mm
b = a numeral (usually a decimal number)
on the final drive pinion gear either added to
or subtracted from 22.2
c = a numeral (usually a decimal number)
on the final drive pinion gear bearing housing
either added to or subtracted from 67.8
d = a numeral (usually a decimal number)
on the final drive case either added to or subtracted from 100
T.
R.
8-25
1
A
c
d
Therefore, A is 0.58.
A = 55 + (67.75 - 22.18) - 99.99
= 0.58
Round off the hundredth digit and select the
appropriate shim(s).
In the example above, the calculated number
is 0.58. The chart instructs you to round off 8
to 10 at the hundredth place. Thus, the shim
thickness is 0.60 mm (0.024 in).
Example:
a = 55
If -02 is stamped on the final drive pinion
gear,
b = 22.2 - 0.02
= 22.18
Hundredth
Rounded value
0, 1, 2
3, 4, 5, 6, 7
8, 9
10
EAS30120
8-26
e
f
g
g
1
2
h = 49.8
Therefore, shim and thrust washer thickness
B is 5.16.
B = 49.8 - (71.57 - 50.88 + 23.95)
= 5.16
Round off the hundredth digit and select the
appropriate shim(s).
In the example above, the calculated number
is 5.16. The chart instructs you to round off 6
to 5 at the hundredth place.
Thus, the shim and thrust washer thickness is
5.15 mm.
Example:
If -03 is stamped on the final drive case,
e = 71.6 - 0.03
= 71.57
Hundredth
Rounded value
0, 1, 2
3, 4, 5, 6, 7
8, 9
10
8-27
Thrust washer 2
Thickness (mm)
4.50 4.80 5.10 5.40
TIP
Be sure to use one of each of the final driven pinion gear shim (final drive case side) 1 and
thrust washer 2 to obtain the shim and thrust
washer thickness.
EAS30130
1
e. If out of specification, remove the originally fitted shim(s), and then select the correct
shim(s)
2. Select:
Final driven pinion gear shim (final drive case
cover side)
Final driven pinion gear shims (final drive case cover side)
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
TIP
T.
R.
EAS28P1018
8-28
2. Select:
Wheel gear shim(s)
EAS30170
T.
R.
TIP
ECA16250
NOTICE
4. Attach:
Final gear backlash band 2
Dial gauge 3
Final gear backlash band
90890-01511
Middle drive gear lash tool
YM-01230
8-29
Thinner shim
Thicker shim
a
a. Measuring point is 31.5 mm (1.24 in)
5. Measure:
Gear backlash
Gently rotate the final drive pinion gear from
engagement to engagement.
Final gear backlash
0.100.20 mm (0.0040.008 in)
TIP
Thrust washers 3
Thickness (mm)
4.50 4.80 5.10 5.40
TIP
Be sure to use one of each of the final driven pinion gear shim (final drive case side) 2 and
thrust washer 3 to obtain the shim and thrust
washer thickness.
Final driven pinion gear shims (final drive case cover side) 4
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
1
2
4
3
2. Adjust:
Gear backlash
a. Select a suitable shim(s) and thrust washer(s) using the following chart.
8-30
8-31
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 9-1
CIRCUIT DIAGRAM .................................................................................. 9-1
TROUBLESHOOTING ..............................................................................9-3
ELECTRIC STARTING SYSTEM .................................................................... 9-5
CIRCUIT DIAGRAM .................................................................................. 9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 9-7
TROUBLESHOOTING ..............................................................................9-9
CHARGING SYSTEM....................................................................................9-11
CIRCUIT DIAGRAM ................................................................................ 9-11
TROUBLESHOOTING ............................................................................9-13
LIGHTING SYSTEM ......................................................................................9-15
CIRCUIT DIAGRAM ................................................................................ 9-15
TROUBLESHOOTING ............................................................................9-17
SIGNALING SYSTEM ...................................................................................9-19
CIRCUIT DIAGRAM ................................................................................ 9-19
TROUBLESHOOTING ............................................................................9-21
COOLING SYSTEM....................................................................................... 9-27
CIRCUIT DIAGRAM ................................................................................ 9-27
TROUBLESHOOTING ............................................................................9-29
FUEL INJECTION SYSTEM..........................................................................9-31
CIRCUIT DIAGRAM ................................................................................ 9-31
ECU SELF-DIAGNOSTIC FUNCTION....................................................9-33
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 9-33
TROUBLESHOOTING METHOD............................................................ 9-35
DIAGNOSTIC MODE .............................................................................. 9-36
TROUBLESHOOTING DETAILS ............................................................ 9-41
FUEL PUMP SYSTEM...................................................................................9-55
CIRCUIT DIAGRAM ................................................................................ 9-55
TROUBLESHOOTING ............................................................................9-57
2WD/4WD SELECTING SYSTEM.................................................................9-59
CIRCUIT DIAGRAM ................................................................................ 9-59
TROUBLESHOOTING ............................................................................9-61
R/B
Br
R/W
9-1
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27100
CIRCUIT DIAGRAM
IGNITION SYSTEM
1. Crankshaft position sensor
4. Main switch
5. Frame ground
6. Main fuse
8. Battery
20.ECU (engine control unit)
21.Ignition coil
22.Spark plug
29.Lean angle sensor
54.Engine stop switch
59.Ignition fuse
9-2
IGNITION SYSTEM
EAS27130
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the spark plug.
Refer to CHECKING THE SPARK
PLUG on page 3-7.
NG
OK
4. Check the ignition spark gap.
Refer to CHECKING THE IGNITION SPARK GAP on page 9-91.
OK
NG
5. Check the spark plug cap.
Refer to CHECKING THE SPARK
PLUG CAP on page 9-90.
NG
OK
6. Check the ignition coil.
Refer to CHECKING THE IGNITION COIL on page 9-90.
NG
OK
7. Check the crankshaft position sensor.
Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on
page 9-91.
NG
OK
9-3
IGNITION SYSTEM
8. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
9. Check the engine stop switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
10.Check the lean angle sensor.
Refer to CHECKING THE LEAN
ANGLE SENSOR on page 9-92.
NG
OK
11.Check the entire ignition system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-1.
NG
OK
Replace the ECU.
9-4
R/B
Br
R/W
9-5
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
EAS27160
EAS27170
CIRCUIT DIAGRAM
9-6
14
13
1
2
12
3
5
6
10
9
11
9-7
9-8
TROUBLESHOOTING
The starter motor fails to turn.
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the starter motor operation.
Refer to CHECKING THE STARTER MOTOR OPERATION on page
9-92.
OK
NG
4. Check the starter motor.
Refer to CHECKING THE STARTER MOTOR on page 5-42.
NG
OK
5. Check the starter relay.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
6. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
7. Check the engine stop switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
8. Check the start switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
9-9
NG
OK
10.Check the gear position switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
11.Check the entire starting system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-5.
NG
OK
Replace the diode 1 or ECU.
9-10
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
B/L Gy
Gy
Gy
B/L
Gy
(BLACK)
W
W
W
R/B
R
R
R
R
W W W
R/B
6
R
(GRAY)
R
69
R/W
Br/B R/W
L/Y R/Y
R
R
ON
OFF
R Br/L Br
Br Br/L R
8
Br/L
Br
R/Y
10
B
L/Y
B
B
(BLACK)
R/W
Br
R/W
Y/R
Y/R
R/B
R/B
59
Br/L
67
Br
60
Br/Y
Br/L
68
R/B
Br
61
Br/L
R/Y
9-11
(BLACK)
Br/B
R/W
11
CHARGING SYSTEM
2.
3.
5.
6.
8.
AC magneto
Rectifier/regulator
Frame ground
Main fuse
Battery
9-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
TIP
NG
Replace the fuse.
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the stator coil.
Refer to CHECKING THE STATOR
COIL on page 9-92.
NG
The stator coil is faulty. Replace the crankshaft position sensor/stator assembly.
OK
4. Check the rectifier/regulator.
Refer to CHECKING THE RECTIFIER/REGULATOR on page 9-93.
NG
OK
5. Check the entire charging system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-11.
NG
OK
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
B/L Gy
Gy
Gy
B/L
Gy
G R
B W
(BLACK)
W
W
W
R/B
R/B
R/B
B
Br
R
R
69
ON
OFF
R Br/L Br
R/B
G
(BL
R/B
Br/B
R/Y
L/Y
B
L/Y
17
16
R/Y
L/Y
Y/R
L/B
R/Y
(BLACK)
Br
14
10
B
(BLACK)
68
9
8
R/W
Br
WRG B
Br Br/L R
Br/L
Br
R/W
(BLACK)
Br/B
R
R/W
G
B
Br
Br/B R/W
L/Y R/Y
R
R
WRG B
R/B
(GRAY)
(GRAY)
13
B
R G
W B
(GRAY)
R
R
W W W
R/W
12
L/R
R/L
11
Y/R
R/B
Br/L
L/R
R/B
59
Br/L
50
Br
67
Br/R
60
P
Br/Y
Br/L
Br/L
Br/R
Gy
Br/R
51
R/Y
Br
W/B
61
49
Br
Y/B
G W/B
46
G
L
Br/Y
66
63
Br/Y
62
52
R/B
Br
R/Y
L/Y
(BL
Br/R
Br
Lg
R/B
53
Y
55
54
56
OFF
PUSH
Y/W
Y
Y/W
R/Y Y
(BLACK)
R/B Br
64
(GRAY)
L Y
Y/W
L/
L/
(B
L/Y Lg B
B
Br R/B
L
G
Y R/Y
(G
B Lg L/Y
(GRAY)
Y L
Y Y
65
Y G
58
L
Y
Y G B
(BLACK)
B G
Y G
B
57
Y
B
9-15
Y
B
Y G
57
Y G
B
LIGHTING SYSTEM
4. Main switch
5. Frame ground
6. Main fuse
8. Battery
53.Light switch
57.Headlight
58.Headlight relay
61.Headlight fuse
65.Tail/brake light
9-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP
NG
Replace the bulb(s) and bulb socket(s).
OK
2. Check the fuses.
(Main and headlight)
Refer to CHECKING THE FUSES on page 9-83.
NG
Replace the fuse(s).
OK
3. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
4. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
5. Check the light switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
6. Check the headlight relay.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
7. Check the entire lighting system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-15.
NG
OK
The lighting system circuit is OK.
9-17
LIGHTING SYSTEM
9-18
R/B
Br
R/W
9-19
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS27280
CIRCUIT DIAGRAM
SIGNALING SYSTEM
4. Main switch
5. Frame ground
6. Main fuse
8. Battery
18.Reverse switch
20.ECU (engine control unit)
25.Coolant temperature sensor
26.Speed sensor
30.Gear position switch
32.Multifunction meter
34.Coolant temperature warning light
35.Park indicator light
36.Reverse indicator light
37.Neutral indicator light
38.High-range indicator light
39.Low-range indicator light
41.Fuel sender
48.Differential motor
56.Override switch
59.Ignition fuse
60.Signaling system fuse
62.Rear brake light switch
63.Front brake light switch
64.Diode 3
65.Tail/brake light
9-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
Any of the following fail to light: warning light, brake light or an indicator light.
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
4. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Check the condition of each of the signaling system circuits. Refer to
Checking the signaling system.
Checking the signaling system
The tail/brake light fails to come on.
1. Check the tail/brake light bulb and
socket.
Refer to CHECKING THE BULBS
AND BULB SOCKETS on page
9-82.
NG
Replace the tail/brake light bulb, socket or
both.
OK
9-21
SIGNALING SYSTEM
2. Check the front brake light switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
3. Check the rear brake light switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
4. Check the diode 3.
Refer to CHECKING THE DIODE
on page 9-89.
NG
OK
5. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
This circuit is OK.
The neutral, park, high-range, and/or low-range indicator light fails to come on.
1. Check the gear position switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
The reverse indicator light fails to come on.
1. Check the reverse switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
9-22
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
The differential gear lock indicator light and /or four-wheel-drive motor indicator light fails to come on.
1. Check the four-wheel-drive motor
switch (differential motor).
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
Replace the differential motor.
OK
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
While the override switch is pushed, the segments of the speedometer digits will not appear as shown
in the illustration.
NG
OK
9-23
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
The coolant temperature warning light fails to come on.
1. Check the coolant temperature sensor.
Refer to CHECKING THE COOLANT TEMPERATURE SENSOR
on page 9-95.
NG
Replace the coolant temperature sensor.
OK
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
The fuel level indicator fails to come on.
1. Check the fuel sender.
Refer to CHECKING THE FUEL
SENDER on page 9-93.
NG
OK
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly.
The speedometer fails to operate.
1. Check the speed sensor.
Refer to CHECKING THE SPEED
SENSOR on page 9-94.
NG
OK
9-24
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-19.
NG
OK
Replace the meter assembly or ECU.
9-25
SIGNALING SYSTEM
9-26
R/B
Br
R/W
9-27
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
COOLING SYSTEM
EAS27300
COOLING SYSTEM
EAS27310
CIRCUIT DIAGRAM
COOLING SYSTEM
4. Main switch
5. Frame ground
6. Main fuse
8. Battery
20.ECU (engine control unit)
25.Coolant temperature sensor
59.Ignition fuse
66.Radiator fan motor
67.Radiator fan motor circuit breaker
68.Radiator fan motor relay
69.Radiator fan motor fuse
9-28
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
4. Check the radiator fan motor.
Refer to CHECKING THE RADIATOR FAN MOTOR on page 9-94.
NG
OK
5. Check the radiator fan motor relay.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
6. Check the radiator fan motor circuit
breaker.
Refer to CHECKING THE RADIATOR FAN MOTOR CIRCUIT
BREAKER on page 9-95.
NG
Replace the radiator fan motor circuit
breaker.
OK
7. Check the coolant temperature sensor.
Refer to CHECKING THE COOLANT TEMPERATURE SENSOR
on page 9-95.
NG
Replace the coolant temperature sensor.
OK
9-29
COOLING SYSTEM
8. Check the entire cooling system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-27.
NG
OK
Replace the ECU.
9-30
R/B
Br
R/W
9-31
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
EAS27330
EAS27340
CIRCUIT DIAGRAM
9-32
Remains on
ECU operation
FI operation
Vehicle operation
Warning provided
when unable to start
engine
Operation stopped
Cannot be operated
Malfunction detected
* The warning light flashes when any one of the conditions listed below is present and the start switch
is pushed:
Lean angle sensor
12:
Crankshaft position sensor
41:
(open or short-circuit)
30:
50:
EAS27380
9-33
Item
Symptom
Able / unable to
drive
12
Crankshaft position
sensor
Unable
Unable
13
Able
Able
14
Able
Able
15
Able
Able
16
Able
Able
21
Coolant temperature
sensor
(open or short circuit)
Able
22
Able
Able
30
Unable
Unable
33
Ignition coil
(faulty ignition)
Unable
37
Able
39
Fuel injector
(open circuit)
Unable
Unable
41
Unable
Unable
42
Speed sensor
Able
Able
43
Able
44
Able
Able
46
Able
Able
9-34
50
Item
Symptom
Unable
Able / unable to
drive
Unable
Item
Symptom
Able / unable to
drive
Er-1
Unable
Unable
Er-2
Unable
Unable
Er-3
Unable
Unable
Er-4
Unable
Unable
EAS27400
TROUBLESHOOTING METHOD
9-35
EAS27441
DIAGNOSTIC MODE
It is possible to monitor the sensor output data or check the activation of actuators without connecting
the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
Setting the diagnostic mode
1. Set the main switch to OFF and set the engine stop switch to OFF.
2. Disconnect the wire harness coupler from the fuel pump.
3. Simultaneously press and hold the SELECT and RESET buttons, turn the main switch to ON,
and continue to press the buttons for 8 seconds or more.
SELECT
RESET
TIP
9-36
d01 d70
d70 d01
If the engine stop switch is set to ON, set it to OFF, and then set it to ON again.
7. Turn the main switch to OFF to cancel the diagnostic mode.
TIP
To perform a reliable diagnosis, make sure to turn off the power supply before every check and then
start right from the beginning.
Diagnostic code table
Fault
code
No.
Symptom
Diagnostic
code No.
12
13
d03
14
d03
15
16
d01
21
d06
9-37
Symptom
Diagnostic
code No.
22
d05
30
d08
33
37
39
d36
41
d08
42
43
44
46
9-38
d30
d09
50
Symptom
Faulty ECU memory.
(When this malfunction is
detected in the ECU, the
fault code number might
not appear on the multifunction meter.)
Diagnostic
code No.
Item
Meter display
Checking method
Throttle angle
Fully closed position
1222
91111
d03
Pressure difference
(atmospheric pressure and
intake air pressure)
d05
Compare the actually measured intake air temperature with the meter display
value.
d06
Coolant temperature
d07
0999
d08
d09
Upright
3.74.4
Overturned
0.41.4
Approximately 12.0
9-39
d60
d61
d62
d70
Item
Meter display
Neutral switch
Checking method
Shift the transmission.
Neutral
ON
In gear
OFF
No history
00
History exists
01
No history
00
History exists
History exists
Up to 16 fault codes
Control number
00255
d30
d36
Item
Actuation
Checking method
Ignition coil
Injector
9-40
d50
d51
d54
Item
Actuation
Checking method
ISC valve
EAS27481
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service
the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part have been completed, reset the meter display
according to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to Self-Diagnostic
Function table.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to DIAGNOSTIC
MODE on page 9-36.
9-41
12
Symptom No normal signals are received from the crankshaft position sensor.
Reinstatement
method
Cranking the
engine.
Connections
Crankshaft position sensor coupler
Main wire harness-ECU coupler
9-42
13
Connections
Intake air pressure sensor coupler
Main wire harness-ECU coupler
9-43
Reinstatement
method
14
Reinstatement
method
Intake air pressure sensor malfunction Check and repair the connecat intermediate electrical potential.
tion.
Replace it if there is a malfunction.
Connections
Intake air pressure sensor coupler
Main wire harness-ECU coupler
9-44
15
Connections
Throttle position sensor coupler
Main wire harness-ECU coupler
Check for open circuit and replace the throttle position sensor.
(YellowBlack/Blue)
9-45
Reinstatement
method
16
Reinstatement
method
Reinstated by
starting the engine, operating
it at idle, and
then racing it.
21
9-46
Reinstatement
method
Setting the
main switch to
ON.
22
Reinstatement
method
Connections
Intake air temperature sensor coupler
Main wire harness-ECU coupler
Setting the
main switch to
ON.
30
Reinstatement
method
Connections
Lean angle sensor coupler
Main wire harness-ECU coupler
Setting the
main switch to
ON (however,
the engine cannot be restarted
unless the main
switch is first
set to OFF).
9-47
33
Ignition coil
Connections
Ignition coil connector (primary coil
side)
Main wire harness-ECU coupler
Check the connector and couStarting the enpler for any pins that may have gine and operpulled out.
ating it at idle.
Check the locking condition of
the connector and coupler.
If there is a malfunction, repair it
and connect the connector or
coupler securely.
9-48
Reinstatement
method
37
ISC valve
Reinstatement
method
9-49
39
Fuel injector
Reinstatement
method
Connections
Fuel injector coupler
Main wire harness-ECU coupler
Main wire harness fuel pump coupler
Cranking the
engine. (Connect the fuel injector coupler.)
41
Connections
Lean angle sensor coupler
Main wire harness-ECU coupler
9-50
Reinstatement
method
42
Speed sensor
Reinstatement
method
Connections
Speed sensor coupler
Main wire harness-ECU coupler
Replace if defective.
Refer to TRANSMISSION on
page 5-73.
9-51
43
Symptom Power supply to the fuel injector and fuel pump is not normal.
d09
Connections
Fuel injection system relay
Main wire harness-ECU coupler
Check the coupler for any pins Starting the enthat may have pulled out.
gine and oper Check the locking condition of
ating it at idle.
the coupler.
If there is a malfunction, repair it
and connect the coupler securely.
44
Reinstatement
method
Reinstatement
method
Setting the
main switch to
ON.
Malfunction in ECU.
9-52
46
Connections
Main wire harness-ECU coupler
Check the coupler for any pins Starting the enthat may have pulled out.
gine and oper Check the locking condition of
ating it at idle.
the coupler.
If there is a malfunction, repair it
and connect the coupler securely.
Faulty battery.
Malfunction in rectifier/regulator.
Replace if defective.
Refer to CHARGING SYSTEM on page 9-11.
50
Reinstatement
method
Reinstatement
method
Setting the
main switch to
ON.
Malfunction in ECU
TIP
9-53
9-54
R/B
Br
R/W
9-55
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
EAS27550
EAS27560
CIRCUIT DIAGRAM
9-56
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
4. Check the engine stop switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
5. Check the fuel injection system relay.
Refer to CHECKING THE RELAYS on page 9-87.
NG
Replace the fuel injection system relay.
OK
6. Check the fuel pump.
Refer to CHECKING THE FUEL
PUMP BODY on page 7-2.
NG
OK
7. Check the entire fuel pump system
wiring.
Refer to CIRCUIT DIAGRAM on
page 9-55.
NG
OK
Replace the diode 2 or ECU.
9-57
9-58
R/B
Br
R/W
9-59
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
EAS30200
EAS30210
CIRCUIT DIAGRAM
9-60
TROUBLESHOOTING
The four-wheel-drive motor indicator light fails to come on.
TIP
NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to CHECKING AND
CHARGING THE BATTERY on
page 9-84.
NG
OK
3. Check the main switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
OK
4. Check the on-command four-wheeldrive motor switch and differential
lock switch.
Refer to CHECKING THE
SWITCHES on page 9-79.
NG
Replace the on-command four-wheel-drive
motor switch and differential lock switch.
OK
5. Check the four-wheel-drive motor
relay 1.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
6. Check the four-wheel-drive motor
relay 2.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
7. Check the four-wheel-drive motor
relay 3.
Refer to CHECKING THE RELAYS on page 9-87.
NG
OK
9-61
NG
Replace the differential motor.
OK
9. Check the entire 2WD/4WD selecting system wiring.
Refer to CIRCUIT DIAGRAM on
page 9-59.
NG
OK
Replace the ECU.
9-62
R/B
Br
R/W
9-63
67
Y/R
R/W
Gy
B/L Gy
R/B
Y/R
R/B
R/W
Br
69
68
ON
OFF
66
(GRAY)
W
W
W
B/L
W W W
Gy
Gy
Br/L
Br
65
Br/L
Br/L
Br/L
62
Br/Y
R/B
Br/B R/W
L/Y R/Y
L
Y
Y G B
53
R/Y
10
L Y
L/Y
R/Y
(BLACK)
Br/B
R/W
52
11
R/B
58
54
R/B
Br
55
R/B
L/Y
(BLACK)
B G
Y Y
Y G
B
(GRAY)
Br R/B
(GRAY)
Y/W
64
Y/W
R/B Br
Y/W
R
R
(BLACK)
63
R/Y
Br/Y
Br
(BLACK)
Br Br/L R
Br/Y
61
60
59
Y L
R Br/L Br
(BLACK)
56
57
OFF
PUSH
Lg
R/B
B
Br
(GRAY)
R/B
50
P
Br
Y G
Y G
B Lg L/Y
Y R/Y
L/Y Lg B
57
Br/R
Br
Br/R
Y G
B
L/R
42
45
(GRAY)
(GRAY)
2WD
4WD
LOCK
47
Br/B
(GRAY)
18
G/W
31
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
Y/W
Sb
L/R
R/L
Y/W
Y/W
Br
L/Y
R/Y
R/G
P/L
W/G
Br/L
32
B/W B
20
Gy
Sb
L/Y
48
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br
40
39
38
37
36
35
34
G/Y
Br
Br/B
R/G
P/L
W/G
Br/L
R/W
Gy
O/W
G/W
33
B/Y
(BLACK)
19
R/W
R/W
(BLACK)
Gy
L/B
L/R
44
Br/R B L/R
Br/R
B/Y
(GRAY)
B/W
L/R
G/R
L/R B
Br/R
Br/R
41
15
L/G
L/R
B B/W
R/L G/Y
G/R Gy
B Br
(BLACK)
L/R L/G
Sb L/B
L/G B
Br/R
Br/R
43
R/L
(BLACK)
L/R G/R
Gy B
L/G L/R
L/Y Sb
(BLACK)
Y/B
Gy
(BLACK)
Br/R B L/G
Gy
Br/B
Br/R
Br
L/R
L/R
(BLACK)
G/R W L
L/B
O/W Br L/B
Br/B
W
G/R
O/W
L/B
L
G W G/R
R/B
W
G/R
O
L/B
G
R B
B R
L/B Br O
L/R
R/L
46
R/B
Br/B
13
R
Y/B
17
14
WRG B
Br/L
12
WRG B
Br/R
49
G W/B
L/Y
R/Y
R G
W B
16
R/Y Y
51
W/B
R/Y
L/Y
(BLACK)
G
B
Br
(GRAY)
G R
B W
L
W
B/L
L/B
Y/G
Br/W B/L
(GRAY)
R/L R/B
G/Y B/L
Br/W
R/B
(BLACK)
G/R
Y/L
B/W
Y/L Br B/W
(BLACK)
R/L
29
Y/G
L B/L
25
24
23
G/Y
(GREEN)
G/Y
(BLACK)
Br/W
R/B
L/R Y/B
30
28
27
L
W
B/L
L W
B/L
22
L P Gy W
26
L
(BLACK)
B/L P
(BLACK)
B/L Y
L/Y
W
B/L
W L/Y
B/L
21
L P
Gy W
L/B Sb
L/B W/R
W/R Gy/G
Sb Gy/G
(GRAY)
L Y/G B/L
L
P
B/L
B/L
Y
L
B/L
B/L
R/B
EAS30230
EAS30240
CIRCUIT DIAGRAM
9-64
If the engine is stopped using the engine stop switch and the main switch is in the ON position, the
EPS warning light comes on to indicate that the power assistance for the steering is not functioning.
If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EAS30260
The EPS system does not operate while the EPS warning light is on.
9-65
g
h
a.
b.
c.
d.
e.
f.
g.
h.
i.
Main switch
EPS warning light (no malfunction detected)
EPS warning light (malfunction detected)
OFF
ON
Off
Comes on.
Initial lighting: 2 seconds
Goes off.
EAS30270
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)
1. Set the main switch to ON.
2. Disconnect the EPS self-diagnosis signal connector 1.
3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male side) to the
EPS control unit 2 or disconnecting it from the unit as follows.
1
2
The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1.2 mi/h).
When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
Identifying fault codes
When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
9-66
g
k
5
i
e A
c f
5
i
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
A.
1
0.5 3
0.5 5
B. Display of the present malfunctions stops
when the past malfunction display mode is
selected.
After the mode selection judgment is completed (present or past malfunction mode), the current fault
code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning light goes off for 1 second between the units of 10 and
the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and
then the next code is signaled.
9-67
d A
b e
5
g
a.
b.
c.
d.
e.
f.
g.
A.
After the mode selection judgment is completed (present display or past malfunction mode), the current
fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second intervals.
Deleting fault codes
To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds
while the present or past malfunction mode is activated. The currently selected mode remains active
after the fault codes of that mode are deleted.
b
a
c
T1
T1
T1
T1
T1
T2
c. Grounded
9-68
21
22
Item
Speed sensor
Symptom
41
42
43
45
EPS motor
52
53
Faulty battery.
Malfunction in the
charging system.
Refer to CHARGING
SYSTEM on page
9-11.
Malfunction in EPS control unit.
54
Malfunction in the
charging system.
Refer to CHARGING
SYSTEM on page
9-11.
Malfunction in EPS control unit.
55
9-69
The malfunction history is stored even if the main switch is turned to OFF, therefore, be sure to erase
the history (present and past malfunction signaling modes) after repairing the cause of the EPS system
malfunction. The malfunction history must be erased in the diagnostic mode. Refer to DIAGNOSTIC
MODE on page 9-66.
Fault code No. 11,13, Symptom EPS torque sensor: open or short circuit detected.
15,16
Order Item/components and probable
cause
Connections
EPS torque sensor coupler
Replace if defective.
Refer to CHECKING THE EPS
TORQUE SENSOR (for
YFM5FGP/YFM7FGP) on
page 9-97.
9-70
Reinstatement
method
Connections
Check the coupler for any pins
Speed sensor coupler
that may have pulled out.
EPS control unit coupler at the wire Check the locking condition of
harness
the coupler.
If there is a malfunction, repair it
and connect the coupler securely.
Reinstatement
method
Starting the engine and activating the
vehicle speed
sensor by operating the vehicle above 5
km/h (3 mi/h),
or setting the
main switch to
OFF, then to
ON, and then
deleting the
fault codes. Refer to DIAGNOSTIC
MODE on
page 9-66.
Reinstatement
method
Connections
Check the coupler for any pins Setting the
main switch to
EPS control unit coupler at the wire
that may have pulled out.
Check the locking condition of
OFF.
harness
ECU coupler at the wire harness
the coupler.
If there is a malfunction, repair it
and connect the coupler securely.
Malfunction in ECU.
9-71
Connections
EPS motor coupler
Replace if defective.
Refer to CHECKING THE EPS
MOTOR (for
YFM5FGP/YFM7FGP) on page
9-97.
Reinstatement
method
Symptom Relay contacts in the EPS control unit are welded together.
Reinstatement
method
Setting the
main switch to
OFF.
Symptom Power supply to the EPS control unit is not normal (low
battery voltage).
Reinstatement
method
Faulty battery.
Setting the
main switch to
OFF.
Malfunction in rectifier/regulator or
charging system.
Replace if defective.
Refer to CHECKING THE RECTIFIER/REGULATOR on page
9-93.
9-72
Symptom Relay contacts in the EPS control unit are welded together.
Reinstatement
method
Setting the
main switch to
OFF.
Symptom Power supply to the EPS control unit is not normal (high
battery voltage).
Malfunction in control unit.
Reinstatement
method
Faulty battery.
Setting the
main switch to
OFF.
Malfunction in rectifier/regulator.
Replace if defective.
Refer to CHECKING THE RECTIFIER/REGULATOR on page
9-93.
9-73
9-74
ELECTRICAL COMPONENTS
EAS27972
ELECTRICAL COMPONENTS
4
2
5
6
8
7
18
17
10
11
16
12
14
15
13
9-75
ELECTRICAL COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9-76
ELECTRICAL COMPONENTS
6
7
8
9
18
10
17
16
11
15
12
14
13
9-77
ELECTRICAL COMPONENTS
1. Lean angle sensor
2. Radiator fan motor relay
3. Fuel injection system relay
4. Four-wheel drive motor relay 3
5. Front brake light switch
6. Rear brake light switch
7. Intake air temperature sensor
8. Intake air pressure sensor
9. TPS (throttle position sensor)
10. ISC (idle speed control) unit
11. Fuel pump
12. Speed sensor
13. Crankshaft position sensor
14. Coolant temperature sensor
15. Ignition coil
16. Battery
17. ECU (engine control unit)
18. EPS (electric power steering) control unit
(YFM5FGP/YFM7FGP only)
9-78
ELECTRICAL COMPONENTS
EAS27980
11
10
Br/Y
Br/Y
1
R Br/L Br
ON
OFF
R Br/L Br
2
R/Y L
Y/W
3
Br R/B
R/Y Y
L/Y Lg B
4
R/B L/Y
R/B Br
(GRAY)
5
Lg
OFF
PUSH
6
L/B L/G L/R Sb Br Gy G/R B
2WD
4WD
LOCK
G/W
8
L
G/R Gy
B
Br
(GRAY)
Gy W
L/R L/G
Sb L/B
(BLACK)
9-79
ELECTRICAL COMPONENTS
1.
2.
3.
4.
5.
6.
Main switch
Light switch
Engine stop switch
Start switch
Override switch
On-command four-wheel-drive motor switch
and differential gear lock switch
7. Four-wheel-drive motor switch (differential
motor)
8. Gear position switch
9. Reverse switch
10. Rear brake light switch
11. Front brake light switch
9-80
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots a. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
Before checking for continuity, set the pocket tester to 0 and to the 1 range.
When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions a are shown in the far left column and the switch lead colors b are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
. There is continuity between red, brown/blue, and brown when the switch is set to ON.
b
R Br/L Br
ON
OFF
R Br/L Br
9-81
ELECTRICAL COMPONENTS
EAS27990
EWA28P1001
WARNING
TIP
ECA28P1001
NOTICE
Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of a headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the life of the
bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration.
Bulbs a and b are used for the headlights
and usually use a bulb holder that must be detached before removing the bulb. The majority
of these types of bulbs can be removed from
their respective sockets by turning them counterclockwise.
Bulbs c are used for tail/brake lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
2. Check:
Bulb (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
9-82
ELECTRICAL COMPONENTS
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb
sockets.
1. Check:
Bulb socket (for continuity)
(with the pocket tester)
No continuity Replace.
TIP
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
3. Replace:
Blown fuse
EAS28000
NOTICE
9-83
Amperage
rating
Qty
Main
40 A
EPS
(YFM5FGP/YFM7FGP
only)
40 A
20 A
Headlight
15 A
Ignition
15 A
15 A
Four-wheel-drive motor
15 A
Auxiliary DC jack
15 A
Signaling system
5A
Spare
40 A
Spare
20 A
Spare
15 A
Spare
5A
ELECTRICAL COMPONENTS
Charging time, charging amperage and
charging voltage for a VRLA (Valve Regulated Lead Acid) battery are different from
those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
be charged as explained in the charging
method. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
EWA13310
WARNING
4. Install:
Battery cover
Refer to GENERAL CHASSIS on page 4-1.
TIP
EAS28030
WARNING
NOTICE
9-84
Since VRLA (Valve Regulated Lead Acid) batteries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by measuring the voltage at the battery terminals.
1. Remove:
Battery cover
Front carrier
Battery holding bracket
Refer to GENERAL CHASSIS on page 4-1.
2. Disconnect:
Battery leads
(from the battery terminals)
ECA13640
NOTICE
1
3. Remove:
Battery
4. Check:
Battery charge
ELECTRICAL COMPONENTS
EWA13300
TIP
5. Charge:
Battery
(refer to the appropriate charging method)
9-85
WARNING
NOTICE
ELECTRICAL COMPONENTS
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
A.
B.
C.
D.
E.
TIP
TIP
TIP
Set the charging voltage at 1617 V. If the setting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
c. Make sure that the current is higher than the
standard charging current written on the battery.
TIP
6. Install:
Battery
7. Connect:
Battery leads
(to the battery terminals)
9-86
ELECTRICAL COMPONENTS
Starter relay
ECA13630
NOTICE
Br/B R/W
L/Y R/Y
B
4
1.
2.
3.
4.
2
8. Check:
Battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
Battery terminals
Result
Continuity
(between 3 and 4)
Headlight relay
Recommended lubricant
Dielectric grease
First step:
10.Install:
Battery holding bracket
Front carrier
Battery cover
Refer to GENERAL CHASSIS on page 4-1.
EAS28040
1
3
2
B
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Result
Continuity
(between 1 and 2)
No continuity
(between 1 and 3)
9-87
ELECTRICAL COMPONENTS
Fuel injection system relay
Second step:
3
5
4
1
B
Y
L
1.
2.
3.
4.
5.
1.
2.
3.
4.
Result
Continuity
(between 3 and 4)
Result
No continuity
(between 3 and 4)
Continuity
(between 3 and 5)
1
3
2
L/R B Br/R
Br/R
B/Y
R/W
1.
2.
3.
4.
Result
Continuity
(between 1 and 2)
No continuity
(between 1 and 3)
Result
Continuity
(between 3 and 4)
9-88
ELECTRICAL COMPONENTS
Second step:
Second step:
5
4
2
1.
2.
3.
4.
5.
5
4
L/R B Br/R
L/G B Br/R
Br/R
Br/R
B/Y
Br/B
1.
2.
3.
4.
5.
Result
No continuity
(between 3 and 4)
Continuity
(between 3 and 5)
Result
No continuity
(between 3 and 4)
Continuity
(between 3 and 5)
First step:
1
3
2
Y/B
Br/R
Gy
Br
L/G B Br/R
Br/R
Br/B
1.
2.
3.
4.
Result
Continuity
(between 3 and 4)
Result
Continuity
(between 1 and 2)
No continuity
(between 1 and 3)
EAS28050
9-89
ELECTRICAL COMPONENTS
TIP
EAS28090
2
Y
Y/W
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe
red/black 1
Negative tester probe
orange 2
EAS28060
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2. Check:
Secondary coil resistance
Out of specification Replace.
9-90
ELECTRICAL COMPONENTS
Secondary coil resistance
8.6412.96 k at 20 C (68 F)
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
EAS28120
EAS28930
TIP
9-91
ELECTRICAL COMPONENTS
e. Measure the lean angle sensor output voltage.
EAS28940
Gy
EAS28130
EWA13810
WARNING
Br/B R/W
L/Y R/Y
65
EAS28150
65
UP
L Y/G B/L
9-92
ELECTRICAL COMPONENTS
Positive tester probe
red 1
Negative tester probe
black 2
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe
white 1
Negative tester probe
white 2
Positive tester probe
white 1
Negative tester probe
white 3
W W W
EAS28230
W W W
1 2 3
b. Measure the stator coil resistance.
EAS28170
Charging voltage
above 14 V at 5000 r/min
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
9-93
ELECTRICAL COMPONENTS
Positive tester probe
white 1
Negative tester probe
black/blue 2
R/L B B/W G/Y
W L/Y
L W
B/ L
B /L
2
b. Set the main switch to ON.
c. Elevate the rear wheels and slowly rotate
them.
d. Measure the voltage (DC 20 V) of white and
black/blue. With each full rotation of the rear
wheel, the voltage reading should cycle from
0.6 V to 4.8 V to 0.6 V to 4.8 V.
EAS28250
EAS28240
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
9-94
ELECTRICAL COMPONENTS
EAS28P1001
EAS28260
WARNING
TIP
The radiator fan motor circuit breaker 1 is attached to the wire harness with black tape near
the tail/brake light connectors 2.
2. Check:
Coolant temperature sensor resistance
Out of specification Replace.
Coolant temperature sensor resistance
2.45 k at 20 C (68 F)
290354 at 80 C (176 F)
2. Check:
Radiator fan motor circuit breaker resistance
Out of specification Replace the radiator
fan motor circuit breaker.
a. Connect the pocket tester ( 1) to the radiator fan motor circuit breaker as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2
b. Immerse the coolant temperature sensor 1
in a container filled with coolant 2.
TIP
Make sure the coolant temperature sensor terminals do not get wet.
c. Place a thermometer 3 in the coolant.
d. Slowly heat the coolant, and then let it cool
down to the specified temperature.
e. Measure the coolant temperature sensor resistance.
9-95
ELECTRICAL COMPONENTS
EAS28300
a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Resistance
3.085.72 k
EAS28420
Y B/L
EWA14110
WARNING
3. Install:
Throttle position sensor
TIP
When installing the throttle position sensor, adjust its angle properly. Refer to ADJUSTING
THE THROTTLE POSITION SENSOR on page
7-7.
2. Check:
Intake air temperature sensor resistance
Out of specification Replace.
EAS28410
9-96
ELECTRICAL COMPONENTS
a. Connect the pocket tester ( 100) to the intake air temperature sensor terminal as
shown.
Continuity
Positive tester probe red 1
Negative tester probe black
2
No continuity
Positive tester probe red 1
Negative tester probe EPS
motor body 3
No continuity
Positive tester probe black
2
Negative tester probe EPS
motor body 3
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
3
1
1
B
TIP
Make sure that the air temperature sensor terminals do not get wet.
c. Place a thermometer 3 in the water.
d. Slowly heat the water, then let it cool down to
the specified temperature.
e. Measure the intake air temperature sensor
resistance.
EAS30300
EAS30310
9-97
ELECTRICAL COMPONENTS
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe
red 1
Negative tester probe
black 2
1
2
9-98
ELECTRICAL COMPONENTS
9-99
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................10-1
GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES............................................................................10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ...........................................................................10-2
FAULTY GEAR SHIFTING...................................................................... 10-2
SHIFT LEVER DOES NOT MOVE .......................................................... 10-2
JUMPS OUT OF GEAR...........................................................................10-2
FAULTY CLUTCH ...................................................................................10-3
OVERHEATING ......................................................................................10-3
OVERCOOLING......................................................................................10-3
POOR BRAKING PERFORMANCE........................................................ 10-4
FAULTY SHOCK ABSORBER ASSEMBLY............................................10-4
UNSTABLE HANDLING ..........................................................................10-4
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 10-4
10
TROUBLESHOOTING
Sucked-in air
EAS28451
TROUBLESHOOTING
EAS28460
GENERAL INFORMATION
TIP
STARTING FAILURES
Engine
1. Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
2. Piston and piston ring(s)
Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
3. Air filter
Improperly installed air filter
Clogged air filter element
4. Crankcase and crankshaft
Improperly assembled crankcase
Seized crankshaft
Electrical system
1. Battery
Discharged battery
Faulty battery
2. Fuse(s)
Blown, damaged or incorrect fuse
Improperly installed fuse
3. Spark plug
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
4. Ignition coil
Cracked or broken ignition coil body
Broken or shorted primary or secondary coils
Faulty spark plug lead
5. Ignition system
Faulty ECU
Faulty crankshaft position sensor
Broken AC magneto rotor woodruff key
6. Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty gear position switch
Faulty start switch
Faulty brake light switch
Improperly grounded circuit
Loose connections
7. Starting system
Faulty starter motor
Faulty starter relay
Faulty starter clutch
EAS28490
Fuel system
1. Fuel tank
Empty fuel tank
Clogged fuel tank drain hose
Clogged rollover valve
Clogged rollover valve hose
Deteriorated or contaminated fuel
2. Fuel pump
Faulty fuel pump
Faulty fuel injection system relay
Clogged or damaged fuel hose
3. Throttle body
Deteriorated or contaminated fuel
Engine
1. Cylinder and cylinder head
Incorrect valve clearance
Damaged valve train components
2. Air filter
Clogged air filter element
Fuel system
1. Throttle body
Damaged or loose throttle body joint
Improper throttle cable free play
Flooded throttle body
10-1
TROUBLESHOOTING
Electrical system
1. Battery
Discharged battery
Faulty battery
2. Spark plug
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
3. Ignition coil
Broken or shorted primary or secondary coils
Faulty spark plug lead
Cracked or broken ignition coil
4. Ignition system
Faulty ECU
Faulty crankshaft position sensor
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to STARTING FAILURES on page 10-1.
Engine
1. Air filter
Clogged air filter element
Fuel system
1. Fuel pump
Faulty fuel pump
EAS30320
Possible Causes
A. Bearing damage.
B. Improper gear backlash.
C. Gear tooth damage.
D. Broken drive shaft.
E. Broken gear teeth.
F. Seizure due to lack of lubrication.
G. Small foreign objects lodged between the
moving parts.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
Transmission
Seized transmission gear
Foreign object between transmission gears
Improperly assembled transmission
EAS28530
EAS28550
EAS3B41028
Shift forks
Worn shift fork
Shift drum
Incorrect axial play
Worn shift drum groove
10-2
TROUBLESHOOTING
Transmission
Worn gear dog
EAS28600
OVERHEATING
Engine
1. Clogged coolant passages
2. Cylinder head and piston
Heavy carbon buildup
3. Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
EAS28580
FAULTY CLUTCH
Engine operates but vehicle will not move
1. V-belt
Damaged or worn V-belt
Slipping V-belt
2. Primary pulley cam and primary pulley slider
Damaged or worn primary pulley cam
Damaged or worn primary pulley slider
3. Clutch spring(s)
Damaged clutch spring
4. Transmission gear(s)
Damaged transmission gear
Cooling system
1. Coolant
Low coolant level
2. Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fin
3. Water pump
Damaged or faulty water pump
4. Thermostat
Thermostat stays closed
5. Hose(s) and pipe(s)
Damaged hose
Improperly connected hose
Damaged pipe
Improperly connected pipe
Clutch slips
1. Clutch spring
Damaged, loose or worn clutch spring
2. Clutch shoe
Damaged or worn clutch shoe
3. Primary sliding sheave
Seized primary sliding sheave
Poor starting performance
1. V-belt
V-belt slips
Oil or grease on the V-belt
2. Primary sliding sheave
Faulty operation
Worn pin groove
Worn pin
3. Clutch shoe
Bent, damaged or worn clutch shoe
Fuel system
1. Throttle body
Damaged or loose throttle body joint
2. Air filter
Clogged air filter element
Chassis
1. Brake(s)
Dragging brake
Electrical system
1. Spark plug
Incorrect spark plug gap
Incorrect spark plug heat range
2. Ignition system
Faulty ECU
EAS28610
OVERCOOLING
Cooling system
1. Thermostat
Thermostat stays open
10-3
TROUBLESHOOTING
EAS28620
EAS28710
EAS3B41029
Malfunction
Fatigued or damaged shock absorber spring
Bent or damaged damper rod
EAS28670
UNSTABLE HANDLING
1. Handlebar
Bent or improperly installed handlebar
2. Steering
Incorrect toe-in
Bent steering stem
Improperly installed steering stem
Damaged bearing or bearing race
Bent tie-rods
Deformed steering knuckles
3. Shock absorber
Faulty shock absorber spring
Leaking oil
4. Tire(s)
Uneven tire pressures (left and right)
Incorrect tire pressure
Uneven tire wear
5. Wheel(s)
Incorrect wheel balance
Deformed wheel
Damaged or loose wheel bearing
Bent or loose wheel axle
Excessive wheel runout
6. Frame
Bent frame
Damaged frame
10-4
EAS28740
WIRING DIAGRAM
YFM5FGY/YFM5FGPY/
YFM7FGY/YFM7FGPY 2009
1. Crankshaft position sensor
2. AC magneto
3. Rectifier/regulator
4. Main switch
5. Frame ground
6. Main fuse
7. EPS fuse
8. Battery
9. Fuel injection system fuse
10. Starter relay
11. Starter motor
12. EPS torque sensor
13. EPS motor
14. EPS (electric power steering)
control unit
15. EPS self-diagnosis signal connectors
16. Diode 1
17. Fuel injection system relay
18. Reverse switch
19. ISC (idle speed control) unit
20. ECU (engine control unit)
21. Ignition coil
22. Spark plug
23. Fuel injector
24. Intake air temperature sensor
25. Coolant temperature sensor
26. Speed sensor
27. TPS (throttle position sensor)
28. Intake air pressure sensor
29. Lean angle sensor
30. Gear position switch
31. Meter assembly
32. Multifunction meter
33. Engine trouble warning light
34. Coolant temperature warning
light
35. Park indicator light
36. Reverse indicator light
37. Neutral indicator light
38. High-range indicator light
39. Low-range indicator light
40. EPS warning light
41. Fuel sender
42. Fuel pump
43. Diode 2
44. Four-wheel-drive motor relay 1
45. Four-wheel-drive motor relay 2
46. Four-wheel-drive motor relay 3
47. On-command four-wheel-drive
motor switch and differential
lock switch
48. Differential motor
49. Four-wheel-drive motor fuse
50. Auxiliary DC jack fuse
51. Auxiliary DC jack
EAS28750
COLOR CODE
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
B/L
B/R
B/W
B/Y
Br/B
Br/L
Br/R
Br/W
Br/Y
G/R
G/W
G/Y
Gy/G
L/B
L/G
L/R
L/Y
O/W
P/L
R/B
R/G
R/L
R/W
R/Y
W/B
W/G
W/R
Y/B
Y/G
Y/L
Y/R
Y/W
Black
Brown
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/Blue
Black/Red
Black/White
Black/Yellow
Brown/Black
Brown/Blue
Brown/Red
Brown/White
Brown/Yellow
Green/Red
Green/White
Green/Yellow
Gray/Green
Blue/Black
Blue/Green
Blue/Red
Blue/Yellow
Orange/White
Pink/Blue
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
White/Black
White/Green
White/Red
Yellow/Black
Yellow/Green
Yellow/Blue
Yellow/Red
Yellow/White
A
1
12
13
5
(BLACK)
18
(BLACK)
(BLACK)
(GRAY)
(GRAY)
21
22
14
(GRAY)
(GRAY)
15
23
69
(BLACK)
(BLACK)
(BLACK)
19
(BLACK)
(BLACK)
24
(GREEN)
25
4
9
ON
OFF
10
20
17
16
(BLACK)
26
11
68
27
(BLACK)
28
59
67
43
49
42
(BLACK)
41
(GRAY)
50
29
60
45
61
51
44
(BLACK)
(BLACK)
31
46
30
32
66
63
62
52
53
54
55
33
56
OFF
PUSH
(BLACK)
(BLACK)
(GRAY)
(GRAY)
34
47
(BLACK)
(GRAY)
64
35
2WD
4WD
LOCK
(BLACK)
36
(GRAY)
37
38
58
65
39
57
(GRAY)
57
40
(BLACK)
48
(GRAY)